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Reinforce XS Manifold Welds

Discussion in 'A3/S3 Forum (8L Chassis)' started by Barks, Jun 28, 2012.

  1. Barks
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    Barks Member

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    [Jun 28, 2012]
    Hello,

    Is there anyone around the Gloucestershire area who is able to reinforce the XS V2 K04 manifold welds, the Franken Manifold has to go!!

    I am not after a freebie, just good welding.

    Thanks

    Barks
    #1
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  3. Reesy
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    Reesy Well-Known Member VCDS Map User

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    [Jun 28, 2012]
    Speak to s3 Dave. He isn't local, but Prawn + Westy have gone to him, might be others as well, and he has a same day it comes in its back out turn around, all for a good price for what he does.
    #2
  4. Barks
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    Barks Member

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    [Jun 28, 2012]
    Ah Yes, I had my rear Tie bars from Mr S3 Dave, Thanks
    #3
  5. superkarl
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    superkarl MAN OF STEEL

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    [Jun 28, 2012]
    bill is in gloucestershire.
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  6. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jun 28, 2012]
    hello................

    you do know where I am Dave..

    like this> nickle rod used
    [​IMG]

    dont you?
    eh?
    #5
  7. Barks
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    Barks Member

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    [Jun 28, 2012]
    I do, I do Bill, I haven't been on the forum for a while and didn't think it was a service you offered!! :)
    #6
  8. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jun 28, 2012]
    lol.... me weldy things..
    done 3 relentless so far for assorted folks
    #7
    sambryant likes this.
  9. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jun 28, 2012]
    I'm thinking of buying a relentless manifold, how come you have to re-weld them? Are they THAT bad?
    #8
  10. S321BAM
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    S321BAM I lost the rod lottery

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    [Jun 28, 2012]
    Bill.....why is nickel rod used??? I'm a TIG welder by trade and curious???? thinking of investing in one of these myself, do they all need reinforcing or is it pretty obvious when you open the box??

    Cheers, Chris
    #9
  11. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jun 29, 2012]
    I should say hi-nickle content stainless rod to be precise. Used for dissimilar materials and supposed to be more crack resistant as a consequence.

    Relentless dont backpurge their thin wall material welds.. and the most common area of failure is around the collector, as it gets the hottest. (like yellow hot!)

    The "hope" is the additional welding around their welds (I back purge when going over them also) is to get thicker weld on the joins and to try and get full penetration weld in that area.

    I say "hope" as its welding on top of their welding.. and quite what *actual* material it is is unknown.. I know what they claim it to be but I am a sceptical bugger, hence using the stainless/nickle rods for dissimilars on them. I use the same rods for welding stainless/ferrous to cast components also... 100% reliable so far.

    The V3 relentless is supposed to be better, but I have'nt seen one, and heard they still have'nt backpurged their welds despite changing material to a titanium induced 321 stainless.. (which sounds great as a sales pitch, but full properties will never be achieved unless full solution annealed to normalise welds........ which they dont do, not likely ever to)
    #10
  12. S321BAM
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    S321BAM I lost the rod lottery

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    [Jun 29, 2012]
    looking at the original welds on the photo, looks like they don't use filler wire at all and just 'fuse' the joints together hense why they would crack. By saying back purge do you mean filling the inside of the manifold with argon??
    #11
  13. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jun 29, 2012]
    yes backpurge=argon inside tube..
    they do "just" fuse the welds in most joints, without penetrating the thin 1.2mm wall thickness.. SO... @ welds its very thin without the full penetration, and if they did happen to break thru, the inside would coke up and oxidise without backpurge anyhow.

    Fusion alone is'nt bad, so long as you make sure its 100% penetration and not an undercut sagged weld bead.

    (I used to work for an engineering company as their Engineering Manager, and one of the products I did back in the 90's was autogenous welded 316L tube to make a coriolis mass flow meter, and this involved TIG fusion butt welded joints, no filler, and was 100% inspected to ensure full penetration etc etc.. All materials were post welding full solution annealed however also to ensure no heat effected zones as would otherwise occur. When I tensile tested the process whilst re-engineering the products production we had no loss of parent material mechanical properties... Just as good as if it had never been welded. Handy when the device when operating vibrated at 120Hz and would cycle >10.4million oscillations in a day... If there was a weakness it would crank in minutes/hours without the work we did to them)

    I guess you dont do back purge welds on stainless where you work?
    Last edited: Jun 29, 2012
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  14. Speedy Steve
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    Speedy Steve Active Member

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    [Jun 29, 2012]
    So basically save money and get the version 2 and then get you to weld it then Bill?
    #13
  15. S321BAM
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    S321BAM I lost the rod lottery

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    [Jun 30, 2012]
    only had to purge weld a several times over the last 16 years, fabricated one off special purpose machinery were purge welding isn't really required. Remember a job years ago someone fused all the joints on a stainless water system, by the time it got to czech republic the majority of the welds had split, around 100m of pipe work!!
    #14
  16. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 1, 2012]
    I've JUST ordered one from relentless in America, If i post it to you would you weld it up and send it me back? I'll cover all costs obviously.. And it'll give you chance to check out a brand new one :)

    Ben
    #15
  17. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jul 2, 2012]
    ok, no probs
    #16
  18. Benjiman46
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    Benjiman46 R-Tech Terrorist

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    [Jul 2, 2012]
    Cool mate, cheers. I'll give you a ring when it arrives :)

    Ben
    #17
  19. lovemelongtime
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    lovemelongtime Member

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    [Aug 1, 2012]
    Hi Bill,

    How much for the welding fella? Can you PM me please? Also can you fit the v2 if so would you recommend doing the rods and piston rings?
    #18
  20. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Aug 1, 2012]
    rods - always yes..
    rings, only if it needs them (often not)
    #19

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