Ouch! The manifold is off

[devonutopia]

I sure hope the two parts can be re-welded back together! :o You could say it was blowing a bit, eh?!

[BossFox]

So you think you've traced the problem then?

[softscoop]

Wow!! Although, nothing a bit of Holts Gun-Gum won't fix

[chrisw880]

Ouch, hopefully it can Jason

[fabdavrav]

Metal fatigue, anyone???? Or was it excessive thermal load???

[adm]

Never seen that before!! Is it because the car has been pushed hard (more than once) or is it because of the extra power/mods?

[vRS Joe]

Will a mended manifold really stand up to a GTB2265VK Jason?

[devonutopia]

Well, if this is welded up again, it will incorporate some "extra" metal to give extra support from the turbo flange, to the base of the manifold. We will have to see. Still waiting to hear back from the manufacturer about their opinions on the photos....

[shark_90]

You've got a bit of an exhaust leak there mate.

[Bazmcc]

I'd start by at least plasma cutting the collector off completely and have it redone. What gauge are the flanges?

Also, there's no fillets, bracing, or support pieces on it. Did you have a turbo brace or damper bolted on?

[karlbar2k]

Wow!! Although, nothing a bit of Holts Gun-Gum won't fix

Might need a bit of exhaust bandage as well though to be sure :D

[devonutopia]

The place that made it said the turbo would not need any support... I took them to their word....

[Bazmcc]

A tubular manifold will need bracing of some sort 99% of the time as they're always prone to cracking. Better safe than sorry. Especially with the heavy low revs and vibration on a diesel.

Check out turbo dampers too just for an extra bit of support. You might be able to brace a damper between the compressor housing and the intake manifold.

[devonutopia]

Well, finally all starting to go back together now, and you could say that a support bracket of some substance has been installed!

[pip_vrs]

What on earth is that!!

Bodge it back together why don't you.

[devonutopia]

That is a custom brace to keep the 2260vk turbo from moving around whilst driving. Looks nasty, but believe me it will do a great job! There was no brace there before which likely contributed to the manifold's demise.

[pip_vrs]

Haha i know it cant be seen and will do its job well.

I recon the first one went due to movement.

[Sy.]

Cold, hot, thrash, cold, hot, thrash... X times.

Id take them to court over a new one plus expenses to bodge it back up

[devonutopia]

They are already paying for labour to repair the manifold although still not had a quote from the chap who welded it up as to how much it will be.