Pony engine exhaust manifold repair

If the metal is good weld it up, If not I sell replacement pipes that will have to be welded in, usually they rot out on the bend a little higher in in your pic

I had an exhaust shop make me a new exhaust pipe for my pilot motor last year after the old one rotted, they used the old mounting flanges, only cost $60 from memory.
regards
Mike

$60 seems really reasonable for such a repair. If the repair was in the U.S. will you post the name of the company that repaired the manifold?

Hi Delta, It was here in Oz, but if you unbolt that pipe I'm sure you will find a exhaust repair joint in your area will do the same deal.
regards
Mike

Hi Delta, my D4 one was like that, That crack will weld easily enough, it's probably worth welding if the rest of the manifold is in better shape. I did mine with my MIG welder after first cleaning the rust off the area. I guess gas weld or TIG would be better but I don't have those in my workshop!

Regards Julian.

PS, it's probably worth adding that this is not the easiest job on the cards for a MIG welder, someone with a few hours experience would be advantageous.

[quote="Julian"]Hi Delta, my D4 one was like that, That crack will weld easily enough, it's probably worth welding if the rest of the manifold is in better shape. I did mine with my MIG welder after first cleaning the rust off the area. I guess gas weld or TIG would be better but I don't have those in my workshop!

Regards Julian.

PS, it's probably worth adding that this is not the easiest job on the cards for a MIG welder, someone with a few hours experience would be advantageous.[/quote]

Yep, weld it slow and let it cool down before you strike again, just spots not a continuos weld.
Regards Dennie

[quote="Julian"]Hi Delta, my D4 one was like that, That crack will weld easily enough, it's probably worth welding if the rest of the manifold is in better shape. I did mine with my MIG welder after first cleaning the rust off the area. I guess gas weld or TIG would be better but I don't have those in my workshop!

Regards Julian.

PS, it's probably worth adding that this is not the easiest job on the cards for a MIG welder, someone with a few hours experience would be advantageous.[/quote]

Yep, weld it slow and let it cool down before you strike again, just spots not a continuos weld.
Regards Dennie

I'm using my MIG welder and the smallest wire that I have; .035" and I'm burning through pipe. Very frustrating! Does anyone have a source for a replacement pipe that I can weld to the flanges?

I'd recommend building a jig to hold the manifold while welding or fabricating or it will never match the manifold flanges again.