Welding A Manifold

[olddudbob]

A friend of mine dropped the manifold from a 6 cylinder Jeep and cracked it in a couple of places. He has asked me to weld up the cracks for him. It appears that it is made from steel tubing (not cast iron). I have both a small 100 amp wire welder (no gas) and an 225 Amp Lincoln AC/DC tombstone welder that I can use. Which welder would work best? If I use the stick welder what would be the best rod to use? Any special prep work that needs to be done before welding other than cleaning and grinding?

Any suggestions would be appreciated.

[Fishy Jim]

Can you show us pics? How thick is the tubing? I'd be surprised if it wasn't cast. Intake or exhaust manifold?

[512TR]

The exhaust manifold is steel tubing, the intake is cast aluminium.

Cracking is a common problem on 4.0L Jeep exhaust manifold,
Here's some pics when I welded my YJ 4.0L 94 mod.

Used 2.5 mm sticks .

Was running the manifold for 2 years after the welding, until I replaced it with a Banks Stainless Header.







Have now replaced it with a Banks stainless steel header.

[olddudbob]

Attached are two pictures of the damage to the manifold.

[Fishy Jim]

I seem to remember my 4.2 as being cast. Oh well.

You should be able to do that with the mig easy enough if you're good on thin stuff like that without punching holes in it.