minor crack at metal casting during installation

[esprithk]

during the installation of the SS High flow Cat Pipe to the W.C. engineering ceramic turbo unit,

the holes on the turbo metal casting that tights the screws of the Cat Pipes (total 3 screws) were not well finished.

one of the hole started to crack when we tried to screw in the nuts.

anyway, it's lucky that we discovered this very quickly and stopped the process.

somehow, my mechanic manages to tight up the Cat Pipe to the Turbo unit after spending most of the day to find solution.

without a proper sealing of the Cat Pipe to the Turbo unit, the oxygen sensor will have error data.

my mechanic tells me if I can always use "welding" process to repair the crack if necessary.

is this true?? **it is only a minor crack from one of the screw hole.

what will be the worst scenerio if the Cat Pipe suddenly pops loss from the Turbo unit during operation of the vehicle??

**although I doubt that this will happen as there are another 2 large screws holding the unit in place.

thx for the feedback on this

[Artie]

during the installation of the SS High flow Cat Pipe to the W.C. engineering ceramic turbo unit,

the holes on the turbo metal casting that tights the screws of the Cat Pipes (total 3 screws) were not well finished.

one of the hole started to crack when we tried to screw in the nuts.

anyway, it's lucky that we discovered this very quickly and stopped the process.

somehow, my mechanic manages to tight up the Cat Pipe to the Turbo unit after spending most of the day to find solution.

without a proper sealing of the Cat Pipe to the Turbo unit, the oxygen sensor will have error data.

my mechanic tells me if I can always use "welding" process to repair the crack if necessary.

is this true?? **it is only a minor crack from one of the screw hole.

what will be the worst scenerio if the Cat Pipe suddenly pops loss from the Turbo unit during operation of the vehicle??

**although I doubt that this will happen as there are another 2 large screws holding the unit in place.

thx for the feedback on this

Do you have any pictures? Not sure where you are talking about, are the cracks on the turbine housing where it mates to the cat pipe? Are the threaded holes cracked or the actual housing? If it's the holes then I don't think it should be a problem, you may send John at WC an email and see what his thoughts are.

Artie

[esprithk]

Hi, Artie, it's one of the three threaded holes that cracks....not the housing

[fflyingdog]

Do you have any pictures? Not sure where you are talking about, are the cracks on the turbine housing where it mates to the cat pipe? Are the threaded holes cracked or the actual housing? If it's the holes then I don't think it should be a problem, you may send John at WC an email and see what his thoughts are.

Artie

Hi Artie

It does sound like the turbo housing has cracked,maybe get it welded and faced back and reamed?.......or worst case scenario a new/reconditioned turbo.I would think the crack would cause a hot spot and when running cause a leak,not a good idea .

Nick S4s

[esprithk]

here is the photo..

Edited March 19, 2007 by esprithk

[fflyingdog]

here is the photo..

http://gallery.photos.cn.yahoo.com/site/ph...pid=8e9ecnb.jpg

Its looks like its the turbo housing that is cracked,so you may be able to get it welded and ground back and use a nut and bolt instead of threaded stud or if you are unable to get it welded you may need a recon turbo........remember alot of heat in this area from exhaust gases and weight from the exhaust system,you dont want exhaust gases leaking and setting alight something.

Nick S4s

[Artie]

Its looks like its the turbo housing that is cracked,so you may be able to get it welded and ground back and use a nut and bolt instead of threaded stud or if you are unable to get it welded you may need a recon turbo........remember alot of heat in this area from exhaust gases and weight from the exhaust system,you dont want exhaust gases leaking and setting alight something.

Nick S4s

I concur, not a good area to have a crack, is this a brand new turbo? If so I'd recommend having them send a replacement. Hot gasses and crack arent good, it's only going to get bigger!

Artie

[esprithk]

thx for the replies..

this is not good news.

the turbo is the original turbo, which I have sent to WC Engineering for the upgrade (to ceramic).

I will talk to the mechanic to take it out and send it to WC Engineering for a repair.

[t70]

you could just wrap the whole shooting match in exhaust tape.... should keep it from leaking... but not really a good quality fix... The mechanic, however, is correct with regards to the o2 sensor readings... Full throttle readings won't be bad, but idle will be terrible...

[esprithk]

**we have done running of the engine & turbo in Saturday and it seems the things are holding in place even under very hot temperature.

ok, turbo is taken out and the crack at the screw hole is examed.

we believe we can fix this small crack by welding as it is still in very early stage.