Welding Exhaust Manifold

In this episode I will show you the box truck that I bought. It is a Ford F600 with the 5.9 Cummins diesel turbo engine. in this video, I am going to show how to weld the exhaust manifold. The exhaust manifold was cracked on the side. I was able to weld it using nickel electrode and arc welding or stick welding process. I hope you will enjoy this series of videos as I enjoyed making it for you. If you have any questions, please feel free to ask me and I will be happy to answer your questions. I appreciate your like, share, comment and subscription to my channel. Please be safe and have a good day.

[@rehanahmad7473]

Great job… much respect.

[@SalamSayhood]

Thank you, I appreciate your comment

[@hondagamer79]

That's great my bro!

[@SalamSayhood]

Thank you 😊 I appreciate your comment

[@cayankeelord3730]

Cast iron is really a dirty metal, which can make it a challenge to weld. Lots of carbon and silica. Against all odds, I've had really great results using my MIG welder with 308 stainless wire w/ 75/25 CO2/argon mix. Haven't had a weld failure yet. Maybe I'm just lucky.

[@SalamSayhood]

Thank you for the feedback, stainless steel wire or rods are excellent choices for unknown steel alloy too. I haven't tried stainless steel welding material with cast iron yet. I think it will work. I only tried bronze brazing and nickel rods. For the exhaust manifold or any part that is subject to heat cycles, I always use nickel rods and never had an issue. Thank you again and have a great day

[@juanzayas7719]

I think the repair got complicated because he tried to get a too hot a well at the beginning blowing holes in the manifold. He should have stopped and jump to the other end of the crack until the damaged area cool off enough to allow a buildup of the nickel rod to cover the holes. The excessive heat and reheat he applied to the damage area of the manifold used in a panic mode caused the manifold to warp. He should have used applied weld let cool for a second and apply again until he covered the whole crack. Then place the manifold in dry sand to cool off.

[@SalamSayhood]

Good morning, next time you weld cast iron manifold, please record the process and post on your channel, then let me know and I'll be happy to go check it out. It is always easy to criticize someone's work. This manifold has a very thin wall in the area where it was cracked. The repair was a success and I was able to mill it (I have video on the milling process) and it is still working great. Thank you for watching