exhaust manifolds.......disertation project

59bhp

59bhp

Member +
hello all,

basically i need some information for my disertation and i was wondering if you lot could help. Its quite important so i knida need as much info as possible.

Basically if you have ever bought an exhaust manifold that has ended up cracking then could you please fill out the form below and post it up. Notice i havent put a field for naming who made it as im not interested in that bit and i dont wanna start a conflict lol

so anyways heres the template:

Manifold material:
date of purchase (doesnt have to be hugely accurate):
Length of time before failure (how long it lasted before cracking):
mileage on car it was installed on:
type of manifold (tod4, ct9, external wastegated etc)
if it was braced:
if so then where:
type of exhaust system (downpipe back):
approx max power of engine it was installed on and rpm this occured:

cheers people
 
Last edited:
WallaceGlanza

WallaceGlanza

Member +
Manifold material: Stainless Steel

date of purchase (doesnt have to be hugely accurate): 10/04/07 ish

Length of time before failure (how long it lasted before cracking): a little over 4 months
mileage on car it was installed on: prob about 75-80k miles

type of manifold (tod4, ct9, external wastegated etc): CT9

if it was braced: Not the mani itself but the downpipe was

if so then where: Downpipe stock brace

type of exhaust system (downpipe back): Blitz decat with stock brace attached then 2.5" custom stainless steel straight through

approx max power of engine it was installed on and rpm this occured:190bhp, I don't rev the engine that hard and can't give an exact rpm of when the mani cracked
 
ChrisGT

ChrisGT

Member +
Manifold material: Stainless steel (SUS 304)

date of purchase (doesnt have to be hugely accurate): 01/03/08

Length of time before failure : 6months

mileage on car it was installed on: 68K-ish

type of manifold (tod4, ct9, external wastegated etc) CT9

if it was braced: Yes.

if so then where: Flange to flange.

type of exhaust system (downpipe back): Front exit exhaust (with bracket)

approx max power of engine it was installed on and rpm this occured: Was used for awhile at stock boost, then 1.1Bar, then stock boost again. Cracked over summer whilst running 10Psi. Don't know exactly when it cracked, sorry.
 
Dane_Bristol

Dane_Bristol

Member +
Manifold material: Stainless Steel (SUS304)

Date of purchase (doesnt have to be hugely accurate): 01/01/2007

Length of time before failure (how long it lasted before cracking): 3 Months
mileage on car it was installed on: 85 000 ish

Type of manifold (tod4, ct9, external wastegated etc)
if it was braced: Not braced CT9

if so then where: N/A
type of exhaust system (downpipe back): Custom made decat back.

Approx max power of engine it was installed on and rpm this occured: 140bhp approx. Came down to thin runners and just randomly cracked.
 
wainy

wainy

Member +
Manifold material: stainless steel
date of purchase (doesnt have to be hugely accurate): july 2008
Length of time before failure (how long it lasted before cracking): 1500miles
mileage on car it was installed on: 60000miles
type of manifold (tod4, ct9, external wastegated etc) td04
if it was braced: yes
if so then where: flange to flange then flange to external wastegate
type of exhaust system (downpipe back): decat back
approx max power of engine it was installed on and rpm this occured: 266bhp-approx 3500revs at 70mph on motoway
 
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Jay

Jay

Admin
I'll give you a different one.

Manifold material: Cast
date of purchase (doesnt have to be hugely accurate): Dec 1995
Length of time before failure (how long it lasted before cracking): Still going
mileage on car it was installed on: 130,000 kms
type of manifold (tod4, ct9, external wastegated etc) : Stock CT9
if it was braced: Yes
if so then where: Downpipe to block
type of exhaust system (downpipe back): Stock
approx max power of engine it was installed on and rpm this occured: Currently somewhere above 133bhp.
 
WallaceGlanza

WallaceGlanza

Member +
Jay said:
I'll give you a different one.

Manifold material: Cast
date of purchase (doesnt have to be hugely accurate): Dec 1995
Length of time before failure (how long it lasted before cracking): Still going
mileage on car it was installed on: 130,000 kms
type of manifold (tod4, ct9, external wastegated etc) : Stock CT9
if it was braced: Yes
if so then where: Downpipe to block
type of exhaust system (downpipe back): Stock
approx max power of engine it was installed on and rpm this occured: Currently somewhere above 133bhp.
Click to expand...

Where can I get one of those?! It sounds awesome!!111!!:eek::beer:
 
WallaceGlanza

WallaceGlanza

Member +
Kick me while I'm down why don't you! I thought you had found the holy grail of exhaust mani's.:p

It suits the application its designed for though, its when silly people start "tuning" that these things fail and are replaced with even worse items.:rolleyes: (Yup been there done that)
 
Jay

Jay

Admin
WallaceGlanza said:
It suits the application its designed for though, its when silly people start "tuning" that these things fail and are replaced with even worse items.:rolleyes: (Yup been there done that)
Click to expand...

Exactly. It suits the manufacturers specification perfectly.

I've seen some mk1 manifolds still running uncracked and that makes them an easy 16 years in service.

Only once you head beyond the manufacturers spec they become an issue.
 
59bhp

59bhp

Member +
Jay said:
Only once you head beyond the manufacturers spec they become an issue.
Click to expand...

well this is what im going to try and remedy, using real gas flow and stress and strain analysis so i can at least have the information should i want to manufacture an unbreakable manifold.

Not one type of aftermarket manifold i have seen has had 100% success rate and using decent engineering methods and software im going to try and design a tubular manifold that not only flows as good as any out there but will not fail.

hell if i manage it i might even publish it lol
 
H

Harvey

Member +
Jay said:
Exactly. It suits the manufacturers specification perfectly.

I've seen some mk1 manifolds still running uncracked and that makes them an easy 16 years in service.

Only once you head beyond the manufacturers spec they become an issue.
Click to expand...

Yeah they are pretty durable units! My stock manifold only recently cracked, maybe 5-8k miles ago before i welded it back up. And my car is a 1994 model and done about 135k miles now!
 
N

Nick@TD.co.uk

Registered Trader <a href="http://www.TuningD
Interesting thread Mike, will be good to see how everyone has found there manifold's, i've seen many Manifold's crack so will be good to see you create one that should stand up to the test of time alot better, I'll give any help i can mate as will be cool to see you getting involved with this.

~Nick @ Tuning Developments
 
59bhp

59bhp

Member +
cheers buddy,

bump ive witnessed first hand some mild steel ones that failed so anyone have any info please come forward
 
D

dave-izzle

Member +
Manifold material: stainless steel SUS304
date of purchase (doesnt have to be hugely accurate): june 2008
Length of time before failure (how long it lasted before cracking): about 3 months
mileage on car it was installed on: 96,000miles
type of manifold (tod4, ct9, external wastegated etc) CT9
if it was braced: yes
if so then where: flange to flange
type of exhaust system (downpipe back): Decat to full system
approx max power of engine it was installed on and rpm this occured: 175bhp, over a small length of time really
 
nexia201

nexia201

Member +
Manifold material: stainless steel SUS304
date of purchase (doesnt have to be hugely accurate): august 2008
Length of time before failure (how long it lasted before cracking): about 1month
mileage on car it was installed on: ???????
type of manifold (tod4, ct9, external wastegated etc) CT9
if it was braced: yes
if so then where: flange to flange
type of exhaust system (downpipe back): Decat only
approx max power of engine it was installed on and rpm this occured: 135 to 150bhp
 
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