Cracked Manifold URGENT help.

[EnthuZiaZT]

Hi Mat
No, I didn't go into any details with Dave, as to how he managed to weld up the manifold. But I know from personel experience that welding castings isn't easy. As you say the castings really need to be heated up, usually to a nice cherry red and then left to cool down after the crack has been welded. The main problem with this approach is finding somewhere big enough to heat the entire manifold at once. Heating it in one area at a time tends to build up stress in the material rather than disipate it. I do not know how to tig weld, but I have used cast iron rods before, the trouble with them is always penitration of the weld.
Mike

 

[EnthuZiaZT]

I find this baffling, the normally aspirated BMW engine produces nothing special by way of heat, pressure or stress.

I think the quality of the castings are of pretty poor material. As I understand it BMW have sourced a new manufacturer and tooling up to make the manifold is causing the delay.

Mike

 

[Machine monkey]

We do have a big oven that can go mega hot. Your right weld penetration could be a problem what I am offering is probably a fix until it can be made right.....

 

[EnthuZiaZT]

We do have a big oven that can go mega hot. Your right weld penetration could be a problem what I am offering is probably a fix until it can be made right.....

Thanks for that Mat, If BMW don't wake up soon and start to roll out these new manifolds I may well take you up on your offer.
Knowing how to do it is one thing, having the right equipment and the knowledge is very important. I would feel more comfortable with a welded manifold knowing it had been done properly, not by some blacksmith from where I live!

Mike

 

[EnthuZiaZT]

Well now been waiting 12 weeks to get this anoying problem fixed. Since Machinemonkey said about welding the manifold up, I've been giving that idea a lot of thought. I wondered if it might be better to braze the crack up, rather than weld it, It would mean less localised heat and brazing is more flexible than a weld! What do you think Mat.

Mike

 

[Machine monkey]

I know a bit about welding I am a little handy. I can solder and I can braze but my boss is the oracle. I am not at work until Wednesday i am on holiday! I can call up tomorrow morning before I go? But won't be able to help until wednesday

 

[EnthuZiaZT]

No Rush Yet Mat, I haven;t decided if thats the way to go yet, I'd much rather wait for a new one. Now I've waited so long I would be dissapointed if I welded it up and then a new one turned up.

Mike

 

[thedanster72]

hi everyone, the dealer has now had my zed (2.0) for 4 weeks and still no sign of a replacement manifold (have a courtesy car) this is the second time in 6 months that its needed replacing due to hairline fractures, i love my zed :headbang: but this is driving me crazy and to top it all my warranty runs out end of july!

 

[Machine monkey]

Have any of you looked into a stainless steel manifolds? Probably pricy but it would fix the problem for good.

 

[speed12]

If this were me I would be looking to get a local fabrication company to weld this crack... I know a few companies that I would approach for this sort of work as I know they would use the right sort of pre and post weld heat treatment...

Hope you sort it soon.

 

[thedanster72]

Hi everyone, still waiting for the replacement manifold for my. Z4 2.0, the dealer has now had the car for 2 months, still no update on the part, has it come available yet anywhere else? is there anybody else still waiting for this part or is my dealer making me wait!! Thanks

 

[Ross D]

Stil waiting too. Thats since 7 May :headbang:

 

[andysat]

FFS!!!-is a fookin joke!!! :thumbsdown: :headbang:

 

[thedanster72]

My zed has been at the dealers (under warranty) for 3 months! 2nd manifold in 8 months due to fractures, thing is my warranty runs out end of july so I'm a little worried if it cracks again..

 

[Ross D]

Got a call from the dealers tonight saying that the manifold will be delivered tomo. I am not holding my breath!! Next up is the moan to try and get compensated for this mess :x

Dealer called. The car is ready at last. 12 weeks to the day after it went in. :driving:

 

[Ewazix]

Got a call from the dealers tonight saying that the manifold will be delivered tomo. I am not holding my breath!! Next up is the moan to try and get compensated for this mess :x

Dealer called. The car is ready at last. 12 weeks to the day after it went in. :driving:

Crazy delay BMW should be ashamed! Lets hope it's all sorted

 

[Anonymous]

How do you know you have a fractured manifold?

 

[DPG]

I hope they do compensate you.

You should be looking for another years warranty...at least

Glad it's sorted now but 12 weeks is a joke.