Cheapo exhaust manifold repair

"Mark Tucker" (markbt73) 09/19/2020 at 14:21 • Filed to: None

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I bought this little beat-up Corolla for $500 to use as a daily driver/beater, right before the lockdowns started. It’s a ‘95 5-speed base model with almost 250,000 miles on it, and it actually runs and drives really well. I’ve had to do some work: new water pump and timing belt, engine mounts, rear swaybar links and bushings (because the rattle was driving me crazy), and new front tires. Total spent so far is $841, not counting gas or insurance, and I’m trying to see how long I can go before I hit $1000.

Which is why I’m trying to patch this crack in the exhaust manifold instead of replacing it.

Apparently all 4A-FEs do this at some point; it’s a design flaw in the manifold.

But let’s see what we can do with this magical goop:

I had to sacrifice a little craft paint brush to apply it, and I couldn’t see what I was doing on the back side, but I think I got all the way around.

Now we wait. It has to cure for between 4 and 24 hours, though you can supposedly speed it up with a heat gun. I’ll report back with results...

VincentMalamute-Kim > Mark Tucker 09/19/2020 at 14:44

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wow. 2400 deg. Impressive. I’m very curious to see how that holds up.

No one tries to weld the manifold? I know welding cast iron is very difficult. Given you have to remove the manifold to weld , most people probably just replace it at that point.

jminer > Mark Tucker 09/19/2020 at 14:44

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Good luck with it. I wouldn’t expect that JB weld is capable of dealing with exhaust manifold heats, but it might. I'd imagine a junkyard manifold for that guy is pretty cheap.

Goggles Pizzano > Mark Tucker 09/19/2020 at 14:50

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dogisbadob > Mark Tucker 09/19/2020 at 14:56

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I hope it holds up! But even if it doesn’t, a new manifold isn’ t expensive for your car. You can get them online for $50

Mark Tucker > jminer 09/19/2020 at 14:58

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The trouble is that all the ones in the junkyard are cracked too. A new manifold is something like $70 shipped from Rock Auto, but I thought I’d try this first, before fighting with rusty nuts.

Urambo Tauro > Mark Tucker 09/19/2020 at 15:02

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I JUST replaced one of these on a neighbor’s ’93 , not even a week ago.

Dr. Zoidberg - RIP Oppo > Mark Tucker 09/19/2020 at 15:03

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While $70 bucks isn't a lot, it sure FEELS like a lot on a $500 car.

jminer > Mark Tucker 09/19/2020 at 15:35

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Yeah removing a manifold on an old car is a dangerous task that almost always ends in broken bolts and more work...

Mark Tucker > Mark Tucker 09/21/2020 at 13:00

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Quick update: It’s been through a couple of heat cycles now, and it seems to be holding up, at least for now. Car is a lot less “snarly” sounding , which is nice.