cracked exhaust manifold

[rogueroughneck]

can I weld the cracks? I have a welder, and it wouldn't take much, I can access the manifold pretty easily, but am I going to do more damage than good? it's cracked right at the O2 sensor... right where it screws in... think it's possible, or... am I looking for a new manifold?

and... where the H.E. DOUBLE HOKEY STICKS can I find a header for the D21 Z24i engine that is 4X4? are they only made for the 2WD version? if so... that's the lamest thing I have ever heard of!!! what's the issue? the front axle assy? can't turning up the torsion bars and leveling the truck out a bit higher fix this??? I have built many rock krawlers, Samurais only, so mods and fab work are not a problem, but geeze.... where to find the parts??? not much support for our trucks is there?

[longtooth]

Get the headers and then cut the pipes and then weild on new piece pipes so that it will fit.

[seang]

You could try to weld the manifold but it will probably crack again. From what I understand welding cast iron is a big deal, not as simple as regular steel.

A KA24E exhaust manifold is very close in design to a naps-z manifold, and might work on your engine.

[rogueroughneck]

KA24E.... I'm a bit lost on the different engine terms... I know there is a z24, and a z24i. then I know of a v6, "3.0" and not much more knowledge as far as knowing the differences.... I guess it's back to google!

[noface]

if you have the Z24 engine, the TRUCK KA manifold will physically fit the engine and dump in the more or less correct position, but the collector flanges on the KA are larger than the flange on the Z, they look real close, and at first glance, you'd think it'll bolt up, but it won't.

What you can do is get a KA manifold, and the collector off a donor Hardbody, and use your welder to make a nice fit.... been there, done that on my 720 with 1994 TRUCK KA24E..

[C-Kwik]

To weld cast iron, you can't use any type of arc welding. It causes too much localized heat which causes further cracking due to uneven expansion from heat. So that leaves welding with a torch and to do this properly, you have to heat the entire manifold up to a certain temperature, weld it, then cool it down slowly over a long period of time (I wanna say its like at least half a day). If it cools too fast, it will crack while cooling. Thicker sections of metal require some additional procedures as well. I'd do some research and/or find a good welding book that explains this type of welding very well and then decide if its within your level of skill/comfort to try.

[rougue*roughneck]

gotcha, thanks for all the replies. sorry my SN is different, re-loaded my windows 7 on my laptop, and all info was erased, and I couldn't remember my password lol...

[longtooth]

gotcha, thanks for all the replies. sorry my SN is different, re-loaded my windows 7 on my laptop, and all info was erased, and I couldn't remember my password lol...

I dont belive you!!!! your a imposter Your real handle is phloop

[rougue*roughneck]

gotcha, thanks for all the replies. sorry my SN is different, re-loaded my windows 7 on my laptop, and all info was erased, and I couldn't remember my password lol...

I dont belive you!!!! your a imposter Your real handle is phloop

haha the funny thing about that is, I know a phloop! from the suzuki forums haha!

[longtooth]

Same here. Lives about a hour from me

[rougue*roughneck]

haha nice! chatted with him a bit, good guy, knows his stuff!