Can the exhaust manifold be cold welded?

Cracks, chips, corrosion are the most common problems with exhaust system elements. They cannot be ignored, and replacing the exhaust manifold requires significant costs. One option is to restore the part using welding, but this is a difficult task and not everyone can do it on their own. There is an alternative solution - cold welding. But is it possible to cover the exhaust manifold with cold welding and thereby eliminate the defects?

Volkswagen Passat 1.6 AHL › Logbook › Exhaust manifold repair

I noticed a crack on the manifold. So nothing, only gases were leaking into the cabin and it was unpleasant. I searched through all the repair forums because the price for a new one is steep. They advise you to brew it, but there is no semi-automatic machine, I found an article about thermosteel 1400 and decided to try it. I bought it, read the instructions and started. I decided to first clean it to a shine with sandpaper, but that was not the case, firstly it took a long time, and secondly it was not convenient, I removed the air filter, then replaced it in one go, took a small grinder and a grinding wheel and forward 5 minutes and you’re done. Then I degreased it with acetone, mixed the composition and applied it according to the instructions. I waited 5 hours and began to warm up the collector intermittently. The main thing is not to overheat immediately, otherwise it will begin to bubble and gases will emit the composition outside. When it warms up it becomes as strong as steel! I'll take a ride and see, I'll write the results.

Muffler repair methods

There are several basic ways to repair a car muffler. They are distinguished by cost, lightness, quality and reliability. Naturally, welding is the best method. But, despite the high quality of repairs, the use of welding is a complex and difficult process. Not every person has the necessary knowledge and tools. Even a welder will not always be able to cope with the repair. The application of cold welding, relatively classical, is very simple. The quality of the seam is practically not inferior to the usual one. There are also special adhesives that are resistant to corrosion, vibration and high temperatures.

guttrv May 18, 2009

Our cars are the same. There is no room for a good welder without crawling up. And to weld over a semi-automatic device and a wire, so nothing nearby won’t get clogged even if he wanted to. One welder told me that when he welds in such places, they hold him by the legs. This you feel like you can’t get close.

Yes, I have a welder who welded in exactly this position. Are we by any chance talking about the same person? There is no semi-automatic, and neither is there a gas one. In addition, there is a crack on the side of the block, where no one can crawl up. Today I tried one method, if it works I’ll post it.

Questions and answers

Sealing compounds are reliable and easy to use, but despite this, car owners may still have questions. For example, what can replace the sealant with and is it better to use welding.

What can replace sealant for the muffler and exhaust system?

Sealants are considered professional means for repairing parts of the exhaust system. But for these purposes you can take other compositions, for example:

1. Cold welding. These products are designed to repair cracks and join metal surfaces. Freeze for 10-12 hours at room temperature. They are produced by various brands and have different performance characteristics. When choosing a composition for working with a car exhaust system, you need to give preference to products with a high level of heat resistance.
2. High temperature sealants for metal elements and surfaces. As a rule, these products are made on a ceramic basis and contain impurities of stainless metals. Designed for repairing various parts - steel, aluminum, cast iron. They are characterized by strength, provide strong adhesion and are insensitive to mechanical stress. They harden well at high temperatures, so experts recommend heating the installation areas to speed up drying. While sealants of this type have many advantages, they also have disadvantages - high cost.
3. Repair kits for exhaust systems. The composition of such sets may vary depending on the manufacturer. But it usually contains non-flammable bandage tape, wire and liquid sodium silicate. The tape is intended for wrapping damaged surfaces, the wire is for securely fastening it. And the liquid is needed for final processing. The kits provide reliable adhesion of surfaces and are able to work, while maintaining their properties, at high temperatures.

When purchasing a product that replaces professional automotive sealant, you need to focus on the nature of the repair. To make the right choice, it is important to carefully study the instructions or consult with the seller.

shum May 19, 2009

Help with advice. In the exhaust manifold (pants), where two pipes are welded into one, the weld has fallen off along the seam, and accordingly it is “cutting”. I take into account removal and welding only as a last resort, because... I'm afraid that there will be a problem with filming - the possibility of “sticking”. What can be done to fix it? I sealed it with a special compound - heat-resistant up to 1400 degrees. The problem is with uneven cooling - when it heats up everything is fine, but when it cools down it falls off.

I filmed it yesterday. Same story. The VDshka rules. The procedure for removing it is 4 nuts from the exhaust, a body bolt (very carefully) - I tore it off, had to drill it out, the lambda, and 2 nuts on the corrugation. I removed it from the pit. I had to jack up the right side. it won’t come out like that. There’s no welding at all; there’s a flaring. I’ve burst on both pipes. Now I’m going to weld it with a semi-automatic device.

Thank you. Reassured. That's why it started to cut through, but I thought it was welding. By the way, I got this kind of crap because I didn’t have a body bolt. There was a load on the connection. Is it possible to brew such a connection? Do the gaskets need to be changed?

Muffler repair methods

There are several basic ways to repair a muffler. They differ in quality, cost, ease of installation and overall reliability of fastening.

The first method is welding, which is one of the most reliable and strong connections. Despite the quality of the final product, this method turns out to be expensive and labor-intensive. Not every master will be able to cope with such a task, and this requires a welder specializing in car repair.

Cold welding of muffler

A bandage with special impregnation, which is made of fiberglass, turns out to be simpler. It helps get rid of cracks and relieves stress from the damaged area. But in terms of reliability, it is inferior to other methods. The bandage also turns out to be very noticeable, which is not always suitable for the owner of the car.

Applying a bandage with special impregnation for muffler repair

Cold welding turns out to be more reliable than a bandage, but is somewhat inferior in properties to ordinary welding. It is easy to use and provides a high level of quality, as it can withstand shock and vibration loads, and also performs well when exposed to high temperatures.

How to seal the exhaust manifold

DarkWing [GB]

[7584] 12/28/2011 12:24 Gentlemen - this is the task:

A hole appeared in the exhaust manifold (a plugged metal tube broke off at the base, 5-6 mm in diameter).

It’s unrealistic to crawl up and somehow brew it. There, only almost blindly you can reach with your fingers with one hand.

For now I covered it with Poxypol, but judging by the smell that appeared, not for long.

Are there any heat-resistant putties or what do you recommend? Last edited by DarkWing [GB] 12/31/2011, edited 1 time in total. _________________ You will squeal like a cloud when the bees decide that you are not a bear.

DarkWing [GB]

[7584] 01/04/2012 23:33 Covered up the hole. Holds up great.

But a new misfortune - below the exhaust manifold (where four pipes converge into one) a wide gap was discovered between the pipe parts - and from there the exhaust is now siphoning.

Do not offer it to the service - there is no money. _________________ You will squeal like a cloud when the bees decide that you are not a bear.

Dimon

[486] 01/12/2012 00:29 Pants should properly be made of cast iron. Cast iron, of course, is cooked, but is it worth it?

What did you cover up with in the end? What kind of car? _________________ Image Repair, tuning and maintenance of AEG and GBB Li-Po battery repair.

Dimon wrote: “Pants should properly be made of cast iron. Cast iron, of course, is cooked, but is it worth it?

From my own experience, I recommend looking towards the disassembly and looking for a normal part + keeping the fire extinguisher close.

What did you cover up with in the end? What kind of car?

I also covered the entire crack with Thermo-steel, which was suggested above. It's holding up for now.

There is a small unsmeared piece left, one of these days I will cover it up. _________________ You will squeal like a cloud when the bees decide that you are not a bear.

What are the criteria for choosing a muffler sealant?

In specialized retail outlets you can find many different compounds for servicing the exhaust system of a car. But it is unwise to purchase the first product you come across - you need to first study its main characteristics. First of all, you need to consider the following points.

Temperature operating range

This criterion is one of the most important. It is a mistake to think that the higher the permissible temperatures, the longer the sealant will last. Many products are not able to cope with increased load for a long time.

Therefore, when purchasing, you should pay attention to another parameter, namely the period during which the composition will not lose its properties when working under high-heat conditions.

State of aggregation

Sealants for the exhaust system are divided into types depending on the composition. They can be made from ceramic or silicone. The performance characteristics depend on the characteristics of the main component.

Ceramic sealants (also called cements or pastes) are suitable for sealing cracks and holes caused by rust. They are highly durable and remain immobile after hardening. But these compounds are sensitive to vibrations, under the influence of which they quickly crack. And since the car constantly vibrates while driving, it is better to use them directly when processing pipe bodies and other parts, and use other means for the space between parts of the system.

Silicone sealants do not lose elasticity after hardening, maintaining some mobility. They are vibration resistant and do not crack. These compounds can be used on gaskets and parts connecting parts of the exhaust manifold.

Sealant type

Sealing agents are classified not only by composition, but also by performance properties. They are divided into the following types:

1. Muffler sealants. Made on a silicone basis and intended for both repair and prevention. Also suitable for working with exhaust manifold, pipes, resonator. They set quickly, but it takes time to dry completely.
2. Mounting pastes. They are used for gluing joints, restoring and installing repaired parts, and installing new elements. When exposed to high temperatures, they harden quickly and retain their performance properties for a long time.
3. Repair glue for the exhaust system. Most of these compounds contain fiberglass. They are used to repair holes and cracks in different areas of the exhaust manifold. They harden quickly and do not lose strength at high temperatures, but can crack under strong mechanical stress.
4. Cements for muffler. These are high-temperature products that work even in high-heat conditions. Very durable, but at the same time inelastic, so they are more suitable for repairing fixed parts or joints. Dries quickly, especially when exposed to high temperatures.

Each type of tool is intended for a specific type of work. To carry out high-quality repairs, you need to take into account the features and performance characteristics of the compounds, and use them where they work best.

Alternative muffler repair methods

Along with cold welding, you can repair a part using:

• Special fiberglass bandage. This material is also able to withstand high temperature loads. Fiberglass bandage is suitable for repairing large areas of the muffler where cold welding is not suitable. This material also contains silicates and epoxides.
• Metal patch. It also does not require the use of a welding machine. The patch is fixed using clamps.
• Special tape. This product consists of a high-strength, high-temperature adhesive that activates and becomes ceramic upon contact with water. The muffler strip can also be made of fiberglass.

However, welding, tape, bandages or patches do not always help get rid of unpleasant “symptoms”. Many car owners often start looking for cracks in the muffler if water starts dripping from it, but the reasons for this phenomenon are rarely associated with a leaky part.

Cold welding application in plumbing

Cold welding is widely used for plumbing. It is used to repair pipelines, including hot water pipes, aluminum, bimetallic and cast iron batteries, mixers, risers and other products:

• Is it possible to cold weld a heating pipe? Cold welding for batteries is not recommended in all cases. Significant cracks and chips cannot be repaired using this material. Therefore, before asking yourself the question of how to cover a battery with cold welding, it is worth weighing the pros and cons of whether it is worth repairing the radiator using this method.
• Cold welding for batteries and pipes. Cold welding for a radiator or pipeline is optimal only if its properties allow it to make a high-quality seam or patch. Otherwise, you risk flooding your home and the apartment of your neighbors below.
• Repair of ceramic sanitary ware. The principles of cold welding for cast iron batteries apply here. That is, defects of significant area and volume cannot be repaired with this material.

Restoration of muffler pipes

Cold welding of a muffler (repairing its pipes with your own hands) is carried out according to the following scheme:

• Surface preparation. The operation consists of stripping the metal layer, which is carried out with sandpaper. Sometimes on the highway they do without this procedure. However, on a cleaned surface, the glue penetrates deeper and lasts longer, so it is better to treat the metal to its characteristic shine. Microscratches and roughness contribute to better adhesion of the mastic to the surface.

Advantages of using cold welding to repair a muffler

Repair by cold welding is an excellent way to eliminate defects in exhaust structures; in addition, the part acquires additional qualities.

This material is a two-component adhesive that is used for metal surfaces. A number of advantages in use:

• Withstands mechanical, shock and vibration loads.
• Resistant to elevated temperatures (up to 150 degrees).
• Easy to use, allowing you to seal it yourself without using welding equipment.
• Availability.
• The strength of the connection is achieved in 5–10 minutes.