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Cast Iron Exhaust Manifold Welding

Testimonials

Mike,

These pics come from a new aerospace test facility that they are constructing at the University of Notre Dame. The SSF-6 is working great.

 

aluminum welding and metal repair

I am attempting to make all of these fittings air tight as they are used for pressure measurements. We can¹t have any leaks. I had very little warpage of my base metal and I think this is really going to work out very well.

 

metal fabrication and repair with muggyweld

Thank you,

 

David Hipskind
Turbomachinery Technician
The University of Notre Dame
Institute for Flow Physics and Control (FLOWPAC)
The Hessert Laboratory for Aerospace Research

 

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Watch the Video Clip of this repair here


This cast iron manifold from a Cummins diesel truck was headed for the junk pile because the shop did not have a cast iron welding rod to repair it. At a cost of $400 to replace, our 77 and 72 rods were an inexpensive alternative.

 



We started by beveling out the crack to prepare the cast iron. We used the 72 on this piece first, because the cast iron was heat affected and the 72 anchors into the affected cast iron. We followed up with the 77 to finish the weld.

 



With just one pass of each rod, the repair was made for around $10. The shop owner had 3 more manifolds on his junk pile that can now be repaired instead of trashed, saving his customer money and time waiting for a new part.

 


TIPS:



For best results weld one inch at a time to keep from overheating the cast iron.



Low and slow is the key to a sound weld with cast iron.

 


Many welders use the 3/32 rods to keep the heat lower.

 

77 and 72 Electrode Products

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Exhaust Manifold Repair Kit 3/32"
Exhaust Manifold Repair Kit 3/32"

Kit Includes: 3 rods 77 electrode 3 rods 72 electrode ..

Exhaust Manifold Repair Kit 1/8"
Exhaust Manifold Repair Kit 1/8"

Kit Includes: 2 rods 77 electrode 2 rods 72 electrode ..

Exhaust Manifold Repair Kit 5/32"
Exhaust Manifold Repair Kit 5/32"

Kit Includes: 2 rods 77 electrode 2 rods 72 electrode ..

Cast Iron Combo 3/32"
Cast Iron Combo 3/32"

Kit Includes: 11 rods 77 electrode 11 rods 72 electrode ..

Cast Iron Combo 1/8"
Cast Iron Combo 1/8"

Kit Includes: 7 rods 77 electrode 7 rods 72 electrode ..

Cast Iron Combo 5/32"
Cast Iron Combo 5/32"

Kit Includes: 4 rods 77 electrode 4 rods 72 electrode ..

1/2 lb 77 Electrode 3/32"
1/2 lb 77 Electrode 3/32"

Save those expensive parts: cast iron exhaust manifolds, cast iron engine blocks, Caterpillar parts..