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Old 12-07-2016, 05:42 PM   #1
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DTA360 manifold

I have a cracked center section of my exhaust/turbo manifold for a 1993 International DTA360. It's about $1,000 to replace with OEM.
Does anyone have a good used one for sale or info on who might be able to fab one and if so, how much I should expect to pay. Or any other advice would be helpful. It's my understanding that welding to repair the manifold is 50/50 at best for a long term solution
Thanks,
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Old 12-07-2016, 06:06 PM   #2
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Welding cast iron can be tough and iffy, but you can definitely braze it. I vee it out a bit, drill the corners of the crack, and then use a TIG torch to heat the work starting in the center. Feed-in the brazing rod near to, but not actually under, the arc. Use a larger tungsten (not thoriated) electrode than what "looks right" to you. Run more shield gas than you normally would. (I use an argon/helium mix). Turn the post-flow timer to as long as it will go. Feather power back slowly at the edges/ends of the crack and aim the shield gas down the braze until postflow has stopped. Make sure the piece cools as slowly as possible.

For a manifold I'd be strongly inclined to seal up the ports loosely and backgas it just in case. Keep the flow going until the piece is below about 350F.

I knew a guy (now deceased) who swore by using a silver/nickle alloy on cast iron. He got some amazing results but I never tried it. You may want to look into that possibility too.

If none of this makes sense, take the piece to your local welder. He'll know what to do and the price should not be bad at all.
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Old 12-07-2016, 06:20 PM   #3
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Was always told to heat to dull red with a gas torch, then weld with a cast iron rod
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Old 12-07-2016, 07:07 PM   #4
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JB Weld?
I've heard it can be used on minor cracks in a block.. Might be worth researching to save $990 of that $1000.

EDIT: Oh, sorry! I read "DTA360 manifold" and automatically assumed intake manifold. Definitely not going to work on an exhaust manifold
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Old 12-07-2016, 08:07 PM   #5
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i tried an epoxy on my cracked manifold. so far so good. i did file the crack a bit bigger and cleaned the area real well.

Blue Magic QS High temperature metal repair trilingual 18003TRI- ReadReviews onBlue Magic #18003TRI

here is the finished repair:




good luck!
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Old 12-07-2016, 08:23 PM   #6
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I called a client of mine who is a welder. The guy has certs for airframe as well as nuke plants. He knows his stuff. Knees gave out years ago so now he inspects while semi-retired. He's a bit of a legend.

I asked him the question, read him my post, and he just chuckled. He said it will work just fine, but we are WAY over-thinking this.

"Get some silicon-bronze wire. Vee it a little if its small. Dont care how you heat it really, but dont pussy-foot around. Get in there, get out, and get it done". He was basically machine-agnostic.

So... there ya go. And I learned something too!
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Old 12-07-2016, 10:50 PM   #7
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You might also check out Muggy Weld as well. They have some welding rods
that work with all kinds of strange metals and the work wonderfully. Saved
my bacon several times. They have how to videos on line.
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Old 12-08-2016, 09:04 AM   #8
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One of the keys to welding cast iron is to cool it VERY slowly. As in pack that sucker in sand while it is still hot and keep the heat in for 24 hours.

But personally...I'd just go to a junkyard and snag a take-off.
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Old 12-08-2016, 09:54 AM   #9
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Thank you all for your responses and advice. I really appreciate it.
I will attempt to weld the manifold and post some pics but it will be a few weeks before I can get to it.
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Old 12-08-2016, 03:56 PM   #10
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Hey: that Muggy Weld stuff is NEAT!. They make some seriously exotic stuff.

Printed for future use.
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