i do not have photos yet, but will post them pronto.

I have been having exhausts leaks, at least in one form or another since i did my motor swap.
1. first leak was the manifold to turbo, which was partially my fault. I fixed this by cutting off the rivets that hold the gasket, they had been preventing the manifold from making a perfect bond with the head. I will deck the manifold to make sure its flat.

2. The manifold to wastegate had a cut in the flange that had been welded onto the manifold. This had let exhaust gases blow by and blow out my gaskets... Could this blowby have taken off material and made the cut larger? I will take the manifold to my welder and add more material and then sand it down.

3. The manifold to turbo had kept coming apart. After i got the manifold to head fixed i found that the bolts that hold the turbo to the manifold had come loose. A quick fix entailed my fat ass under the car with a wrench trying to get at the bolts... to tighten them. This helped my spool time by at least 1k rpms and i would actually hit my full boost... for two pulls before the bolts came loose again... I finally pulled the manifold off and found that one of the bolts had completely sheered off and came off with my fingers. one had nearly oxidized with the manifold, but many healthy applications of wd-40 thwarted its hold and painfully came out. When all was said and done, i still have half a bolt in my manifold and at least 40% of the gasket... the rest blown away on one of my many pulls... some R&R will hopefully get my manifold back in working order. What is the price of just a InlinePro manifold? and do you think my DP will fit from my UR kit? They look to be pretty similar in design.

I will post the pics up as soon as i get them, but this is on a UR manifold after about 30K miles of hard abuse...

 

Pics. Pics. Pics. Take some before u have it welded today, I want to see how bad it is.

 

It was HORRIBLE
There was a small slit on the backside of the flange where the exhaust gas was leaking from

Marcus

 

Cast iron manifolds FTW, stainless steel FTL

At least you found it but sucks that it was broken to begin with.

 

This may help with your bolt problems. well i hope so. In road racing (motorcyles) we safety wire everybolt in place its very easy to do and just requires some patience and time.

1st:
pre-fit the bolt all the way tight (or as tight as you want it) take a sharpie mark the bolt on the visible bare threads and on the head of the bolt as well as the manifold or what ever your bolting on. *this should mark the tightness you want and mark where to drill your small holes for your safety wire*

2nd:
Use a clamp and tighten down on the bolt drill a small hole in your markings one on the head and the other on the threads. *Id prefer if you drilled on a flat edge of the bolt head*

3rd:
Clean up the bolt and screw it in to place. now take some safety wire and loop it through the thread hole. *make sure you have plenty of length* now your going to need some locking pliers or safety wire pliers and your going to clamp the two ends together and twist the safety wire until you have a nice tight pattern. do this all the way to the head of the bolt.

4th:
now take one end and put it through the bolt head hole and repeat the twist again for only about a 1/4-1/8 inch.

5th:
Cut off the extra wire and with some needle nose pliers roll up the excess twist into a tight loop and depending on the bolt push it into the bolt head.

AND HURRAY!!! you are done the bolt should note back out ever again!

This works for my race bikes and should work for you guys aswell.

P.S. the tech guys at the track will love you for it!

peace

Mike

 

^^ I agree.

I have had no end of issues with wastegate and turbo manifold bolts backing out and short of throwing a tack on the bolt head, nothing has worked except the safety wire.