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Old 08-15-2011, 10:23 AM   #1
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SR20 Exhaust manifolds that dont crack?

What exhaust manifolds are people running that actually do their job and don't fall apart? I've tried 3 different manifolds now with pretty much the same results.

Heres my Mazworx manifold after 3 months / 6000 miles.







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Old 08-15-2011, 10:27 AM   #2
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Have you thought about using stock exhaust manifold but porting and polishing it out and then getting it swain coated after?
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Old 08-15-2011, 10:34 AM   #3
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I've thought about it, but really wanted to stay topmount. I plan on pushing 400+ out of this engine before im done with the car.
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Old 08-15-2011, 11:55 AM   #4
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Those are some amazing cracks. Does your car sit outside? What do your EGT's look like at peak?
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Old 08-15-2011, 02:03 PM   #5
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full race manifolds are really nice and youll keep your topmount. my buddy has one and it works amazingly, i have mine sitting at home waiting to be installed =]
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Old 08-15-2011, 02:23 PM   #6
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The mainfold is not always the problem. What does your downpipe setup look like? Does it hang below the frame rail? Does it have a flex section? Because any of your exhaust scrapping would put a strain on it since the whole leverage factor. Then also the egt plays a factor

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Old 08-15-2011, 03:25 PM   #7
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The mainfold is not always the problem. What does your downpipe setup look like? Does it hang below the frame rail? Does it have a flex section? Because any of your exhaust scrapping would put a strain on it since the whole leverage factor. Then also the egt plays a factor
Well said. Flex section is a must regardless. Any turbo bracing?
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Old 08-15-2011, 04:57 PM   #8
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Funny how this came up...my Mazworx manifold did the same shit around the WG neck. Thats the funny shit too, it cracked on a spot that shouldnt have cracked since there really isnt any stress on it other than having a MV44 wastegate and open dump tube on it. My DP had a flex pipe on it. I didnt even know it was cracked since it was wrapped. The guy I just recently sold it too noticed the soot burn on the wrap under the flange and peeled it back.

I'm still pissed about since I spent $800 on it with the same result as a damn Ebay one. Atleast if the Ebay one cracked, i wouldnt be so pissed since i would have expected it to crack.

Send it back to Mazworx and have them reweld it. Considering its cracking on the weld instead of the metal, I'd blame the welds.
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Old 08-15-2011, 10:36 PM   #9
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Send it back to Mazworx and have them reweld it. Considering its cracking on the weld instead of the metal, I'd blame the welds.
Without a doubt that is the issue. It's one thing if the pipe cracks, another if it breaks exactly along the weld
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Old 08-15-2011, 10:48 PM   #10
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Mark should be able to fix it no questions asked. The oem one should do wonders but what can you do if you have a top mount setup... You need a tubular piece.

My isis bottom mount is still holding up just fine!
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Old 08-15-2011, 10:53 PM   #11
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tube exhaust manifolds are pretty thin, unless you use the 1/8 inch kind that they use on log type manifolds. you have to use a really good design(very effective), brace to hold the turbo`s weight. i used to race a car with a big heavy turbo on a full race tubular exhaust manifold that never cracked because of the effective triangulated design brace that it had. it was not a race car, it was a daily driver honda civic with a gt35r making 600+WHP. the manifold is not designed to hold the weight of the turbo, you have to have a brace.
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Old 08-16-2011, 12:20 AM   #12
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Old 08-16-2011, 01:28 AM   #13
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Mine don't crack and are backed by a warranty. Also having a flexpipe on the downpipe helps. Check out my work. I've sold a couple manifolds to people on here

http://zilvia.net/f/gb-forced-induct...0-gtx3071.html

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Old 08-16-2011, 09:59 AM   #14
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Mine don't crack and are backed by a warranty. Also having a flexpipe on the downpipe helps. Check out my work. I've sold a couple manifolds to people on here

http://zilvia.net/f/gb-forced-induct...0-gtx3071.html

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That's a nice little setup!
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Old 08-16-2011, 11:53 AM   #15
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That's a nice little setup!
Thanks. Should have video and dyno numbers on my daily driver soon
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Old 08-16-2011, 08:31 PM   #16
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Thanks. Should have video and dyno numbers on my daily driver soon
I know where I"m pointing people now for Top Mount setups
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Old 08-17-2011, 09:08 AM   #17
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i like my stock mani. no issues at all
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Old 08-17-2011, 09:45 AM   #18
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I know where I"m pointing people now for Top Mount setups
For sure! I will be coming up with a new design soon also.

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Old 08-17-2011, 10:00 AM   #19
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Mazworx does warranty their manifolds.
Contact them regarding your issue.
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Old 08-24-2011, 03:47 PM   #20
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My understanding is that some exhaust manifolds are not designed to withstand the full weight of a turbo/elbow/downpipe configuration. How low is your 240 and have you ever had any scraping issues with any of your exhaust components?
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Old 08-25-2011, 04:04 PM   #21
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The DOC Race ones are really nice. In reality though, all SS manifolds will crack in time no matter how good of quality SS or welds there are. Its the flaw of SS manifolds. You can always add bracing to help support the turbo and downpipe.

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Old 08-26-2011, 02:13 PM   #22
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I've had two Tomei's crack in two different locations... Here is the most recent failure. Before anyone assumes insanity, the cracks were in completely different areas. The first was within the divider at the collector and now these at the runners. Tomei replaced it once, I'm currently waiting to repair this one in an effort to see if they'll replace this one too. for reference, I have a flex section on the vertical drop, polly hangers, poly engine/trans mounts... this shouldn't happen.

What troubles me about manifold failures is that they often seem to be within the weld, as if it split apart. Correct me if I'm wrong (which I'm not) but shouldn't the weld be as strong as the surrounding material; of course if welded correctly? My understanding is that the surrounding material should fail before a quaility weld should. WHY do almost all SS manifolds have little bitty tiny TIG welds that almost look fused with no filler rod? Why not triple pass that shit; lets see a broken tube FOR ONCE!



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Old 08-26-2011, 09:11 PM   #23
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the weld itself should be STRONGER than the metal around it for the most part. If the weld breaks, its a bad weld. The metal should give around the weld before the weld itself does.

Pictures 1,2, and 3 all look to be broken along the edge of the weld, except one spot that crossed. Meaning the metal failed, not the weld. Pic 4 is an obvious weld fail. Stainless steel is extremely brittle, it doesn't have nearly the "give" to it of regular steel. Probably one reason it cracks so easy, what with the weight of a turbo sitting on it and all. There's a lot of leverage at work hanging a turbo off the side of the engine, get some heavy duty bracing in there to support it, should help a lot.
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Old 08-27-2011, 02:47 PM   #24
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Pictures 1,2, and 3 all look to be broken along the edge of the weld, except one spot that crossed
Before agreeing with you I think its important to consider that the starting point of the failure has significantly more to do with the diagnosis rather than pictures of the most visible damage. I wonder where it gave first... We're all pretty aware of the weight of turbo system here and the likeliness of damaging stress it can induce on a manifold, so no need to reiterate what caused it.
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Old 08-28-2011, 02:15 AM   #25
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Well sure, but its damn near impossible to tell from the closeup pics where the likely starting point was. Anybody with much welding/fabrication experience could look at them and figure that out fairly quickly though I should think. From what little I can see, it looks to me like there just wasn't enough filler put in. The weld cut into the steel slightly, and without the right amount of filler was undercut on either side slightly. Therefore, the steel in those places was thinner than in other, and more prone to failure. Concave weld beads is what makes me lean towards that conclusion, a proper weld should be more convex. Now I'm no master fabricator by any means, but I did do steelwork and welding for a living for quite a few years. Better pics would go a long way towards figuring it out, but in this case its already broken so a bit late. Too much emphasis on pretty welds and not enough on strong ones imo.
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Old 08-28-2011, 09:09 AM   #26
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t Concave weld beads is what makes me lean towards that conclusion, a proper weld should be more convex. Now I'm no master fabricator by any means, but I did do steelwork and welding for a living for quite a few years. Better pics would go a long way towards figuring it out, but in this case its already broken so a bit late. Too much emphasis on pretty welds and not enough on strong ones imo.
I'm with you on that one for sure. It seems like most of these manifolds always seem to have a lack of filler material in the welds (dare I say most of them are done this way to look pretty, as forum experts place appearence first when it comes to welding).

Like above, lack of bracing is another thing that so many skip. I know when we're hanging T4+ turbos off a v8 setup, we always try to brace it with a hard/metal brace to the block (or to a chassis point if flex sections or motor plate cars) to help alleviate stress.
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Old 08-28-2011, 09:11 AM   #27
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Another thing I've often wondered, is if the flange itself is partly responsible for the failure as well....it seems like manifolds with split ports seem to have less issues than ones using a solid piece btween them all.

Also curious as if the Tomei piece is 100% stainless on the flange as well, or if it's regular steel. To me if it was all stainless, that may lead to failure as well.
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Old 08-28-2011, 04:30 PM   #28
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Quote:
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From what little I can see, it looks to me like there just wasn't enough filler put in. Too much emphasis on pretty welds and not enough on strong ones imo.
Exactly where I'm at on this... I just don't see the reason for little bitty TIG welds; outside appearance of course.

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I'm with you on that one for sure. It seems like most of these manifolds always seem to have a lack of filler material in the welds (dare I say most of them are done this way to look pretty, as forum experts place appearence first when it comes to welding).
same thing, exactly my thoughts...

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Another thing I've often wondered, is if the flange itself is partly responsible for the failure as well....it seems like manifolds with split ports seem to have less issues than ones using a solid piece btween them all. Also curious as if the Tomei piece is 100% stainless on the flange as well, or if it's regular steel. To me if it was all stainless, that may lead to failure as well.
From what I could tell about the piece when I first got it I'm fairly sure its 100% stainless. I actually spoke with Tomei Friday and they intend to warranty the claim. Question is now, should I take advantage of that at their expenses with this likely to happen again or reweld it, recoat it, and have it on the motor in a couple days; I'm looking at 2 weeks + if I follow up with the claim.
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Old 08-30-2011, 10:42 AM   #29
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Update from my end...

My downpipe, Nor any part of my exhaust has ever hit the ground. The lowest point is the kit on the car, and I'm just not baller enough to let this kit touch the ground. I don't have any bracing on my turbo, and never have. I don't see how bracing the turbo is going to keep the wastegate tube/welds from failing. I shouldn't have to brace the wastegate on a 700 dollar "top of the line" manifold anyways.

Mazworx did warranty the manifold, but I had to ship it at my cost. They said turn around time should be 2 weeks. However, anytime I ever hear 2 weeks from a shop I smell bullshit. Monday the 5th is their deadline, and as Ive yet to receive an email, phone call, or any word at all. I doubt it will be on time.

I gotta say, So far I'm not impressed by Mazworx regardless of how their shop car preforms. Issues thus far.

1. They straight out lied to me about the fitment of the manifold. I asked and was told 3 times before ordering this manifold that it had ZERO fitment issues on RHD cars. Welp, That simply isnt true. You have to move the heater lines for the downpipe to clear, and even then the rubber hoses sit MAYBE 1/4 inch away from it. You simply can not route them out of the way due to where they connect through the firewall. When I called and told them about this, they simply said "just take out the heater lines".

2. After the manifold failed they refused to pay to ship the manifold to them. I can provide proof that the manifold was used less then 3 months. My car was on the dyno 05-27-11, This is the first time/day this manifold was used. I started to hear an exhaust leak I thought to be a failed gasket around the end of last month. The manifold then totally failed 08-10-11. Their excuse is I bought the manifold back in January which is true, However until 05-27-11 it sat in a climate controlled room/shop not even bolted to engine.

The bottom line is, Their manifold failed due to quality control/design flaws. The customer service I have received sucks. They wouldn't even work with me over a 25 dollar shipping charge. Let alone the 80 dollars in gaskets I have to buy again. I will not recommend any parts or service from Mazworx after this. Which is disappointing as I was planning on buying the z32 trans adapter kit, and the solid axle conversion for our cars.

Sorry for the long post, Just felt the need to vent that out there.
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Old 08-30-2011, 10:49 AM   #30
Highway Riding
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Thanks for sharing.. Been looking at all of these mani's and am glad I stayed with the stock sr....
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