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04-21-2010, 2:16 PM Moose Joined on 05-13-2009 Southampton, England Posts 37 Turbo manifold is cracked, any tips? My turbo manifold is cracked quite substantialy in four places. I am looking for any tips as to the best way to weld it by any of you that may have been down this road too! All I was trying to do was replace my generator and I have discovered a s**tload of trouble. On a different subject; ... does any one know what temperature Kevlar or Carbon reinforced plastic can stand, as I need to get heat shields made? Thanks in advance. CX650Tcd currently not running CX650Tcd (in boxes) CX500A, First bike I had bigger than 200cc(Now sold) BMW R1100GS Various beaters/clunkers I think 18 in all now    Report

04-21-2010, 3:07 PM Doward Joined on 05-11-2008 Alachua, FL Posts 814 Re: Turbo manifold is cracked, any tips? I don't believe any composite will handle the temperature of a turbocharger.   Build them out of sheetmetal, and coat them in a heat-reflective ceramic, in my opinion. As for welding, I'm assuming it's a cast iron manifold - you've got to heat it up before even attempting to weld on it.  I'd recommend you find someone with experience welding cast iron, as it can be a SERIOUS PITA. 1978 CX500 motor + 1980 CX500C frame    Report

04-21-2010, 4:48 PM CXTURBOBOOST Joined on 05-02-2007 Lincoln, NE Posts 436 Re: Turbo manifold is cracked, any tips? I have the parts you need.. I will send an e-mail. Thanks! Pete    Report

04-22-2010, 8:29 PM HomerRod Joined on 07-21-2006 Posts 222 Re: Turbo manifold is cracked, any tips? Cast iron is not real difficult to weld, but does require a few additional steps. Here are a few links that might help you better understand the process. Hope this helps.... http://www.weldinginfocenter.org/sci_tech/st_04.aspx http://www.classictrucks.com/tech/0905clt_cast_iron_repair_welding_techniques/index.aspx    Report

04-28-2010, 3:25 PM Moose Joined on 05-13-2009 Southampton, England Posts 37 Re: Turbo manifold is cracked, any tips? Thanks for the help fellas, It's nice to know that there are people out there ready to help, It's a sobering thought that we really are a very fortunate bunch of people to own such a rare machine. DOWARD, it looks as if I may have got some sorted via CXTURBOBOOST who has kindly offered the items that I need. CXTURBOBOOST- thanks for you e-mail, I hope you have my reply by now. HOMEROD- thanks for the links hopefully I won't need to go down that trail, certainly in the short term, but I will certainly be looking at preserving the manifold I have regardless of whether I can obtain another, I can see a lot of fabrication experiments in the future, stainless steel exhausts for one!! (but for now the mighty £$ are strangling my creativity!) CX650Tcd currently not running CX650Tcd (in boxes) CX500A, First bike I had bigger than 200cc(Now sold) BMW R1100GS Various beaters/clunkers I think 18 in all now    Report

05-05-2010, 10:56 AM CXTURBOBOOST Joined on 05-02-2007 Lincoln, NE Posts 436 Re: Turbo manifold is cracked, any tips? Items are packaged in the box and ready to go as soon as payment is received... Pete    Report

05-16-2010, 9:28 AM CXTURBOBOOST Joined on 05-02-2007 Lincoln, NE Posts 436 Re: Turbo manifold is cracked, any tips? Payment received yesterday, package shipped yesterday.... Thanks! PK    Report

05-19-2010, 3:13 PM NightBiker07 Joined on 04-20-2009 Toledo, OH Posts 506 Re: Turbo manifold is cracked, any tips? dont throw the cracked parts away! they can be repaired. either welded or brazed, makes no difference. brazing would probably be easier than welding on the cast. dont scoff at brazing, it is nearly as strong as a weld, and because of the process of brazing, brazing a crack in cast iron could actually be stronger than welding it, as the braze would completely permeate the crack, whereas welding could leave some spots untouched. 80 CX 500 2000 CR 250 DIRT BIKE!!!!!!!!!!    Report

05-20-2010, 1:04 PM Moose Joined on 05-13-2009 Southampton, England Posts 37 Re: Turbo manifold is cracked, any tips? Nightbiker, Thanks for the heads up, I have no intention of throwing anything away if it stands the even the remotest chance of being repaired, the longer you hang onto something the more likely that some way of repairing it will become possible/viable, (ABS fairings for example!) As it happens a replacement manifold is zooming it's way towards me, courtesy of CXTURBOBOOST! Three cheers for Pete! CX650Tcd currently not running CX650Tcd (in boxes) CX500A, First bike I had bigger than 200cc(Now sold) BMW R1100GS Various beaters/clunkers I think 18 in all now    Report

05-20-2010, 1:35 PM Doward Joined on 05-11-2008 Alachua, FL Posts 814 Re: Turbo manifold is cracked, any tips? Shoot, if I could get my hands on one of those turbo manifolds, I could re-cast them with a higher nickel content to keep them from cracking! 1978 CX500 motor + 1980 CX500C frame    Report

05-20-2010, 4:29 PM Moose Joined on 05-13-2009 Southampton, England Posts 37 Re: Turbo manifold is cracked, any tips? Doward, Would the cracked one I have be of any assistance to you? Obviously I would need to get it back but if it could be used as a pattern to help make a replacement part which people could benefit from then I think I may be able to help. We (collective 'we') need to start thinking about remanufacturing more kit if we are to make these machines truly last longer. If we all made a part that our skills allow then some large gaps may be able to be filled. Let me know your thoughts. Cheers CX650Tcd currently not running CX650Tcd (in boxes) CX500A, First bike I had bigger than 200cc(Now sold) BMW R1100GS Various beaters/clunkers I think 18 in all now    Report

05-21-2010, 6:27 AM Doward Joined on 05-11-2008 Alachua, FL Posts 814 Re: Turbo manifold is cracked, any tips? Is it missing a chunk of metal, or just a small crack? 1978 CX500 motor + 1980 CX500C frame    Report

05-21-2010, 7:05 AM CXTURBOBOOST Joined on 05-02-2007 Lincoln, NE Posts 436 Re: Turbo manifold is cracked, any tips? Those manifolds aren't prone to cracking... How many CXT's have cracked manifolds? I've never seen one yet... PK    Report

05-21-2010, 8:23 AM Timothy_D Joined on 04-22-2006 Santa Rosa, CA Posts 1,580 Re: Turbo manifold is cracked, any tips? It's rare, but it happens. I had to weld the expansion joint on one of my turbos due to a crack. CX500 Turbo, GL650I, Two CX650E's, and one Crown Jewel of the CX line- CX650T. Why do I own five CX/GL bikes? Ask an alcoholic why he drinks. Donating Member. Sold: 1981 CX500D, 2- 1982 CX500T's, 1983 CX650C.    Report

05-29-2010, 11:46 AM Moose Joined on 05-13-2009 Southampton, England Posts 37 Re: Turbo manifold is cracked, any tips? DOWARD. No chunks missing just cracks, I will post pics as soon as I get back. CXTURBOBOOST Excellent parts, great packaging, fantastic prices, great help when Parcelforce went quiet too. It would be difficult to ask for better service. If it is OK I will check with you for other parts in the future. I just know that I will need something with the restoration. Thanks a million!! Brian CX650Tcd currently not running CX650Tcd (in boxes) CX500A, First bike I had bigger than 200cc(Now sold) BMW R1100GS Various beaters/clunkers I think 18 in all now    Report

05-29-2010, 12:58 PM Doward Joined on 05-11-2008 Alachua, FL Posts 814 Re: Turbo manifold is cracked, any tips? I can back that up - Pete (CXTURBOBOOST) is the man when it comes to turbo parts!! If there's no chunks missing, it shouldn't be difficult at all to mock it up!   Just a matter of me clearing up time to do it :) 1978 CX500 motor + 1980 CX500C frame    Report

06-17-2010, 9:42 AM TurboDan Joined on 03-06-2006 Griffin, GA Posts 90 Re: Turbo manifold is cracked, any tips? I have several spares available. Dan Topping Diesel Tech Program Coordinator Griffin Technical College Griffin, GA owner CXTC's Parts & Accessories, Inc    Report

06-17-2010, 11:04 AM CXTURBOBOOST Joined on 05-02-2007 Lincoln, NE Posts 436 Re: Turbo manifold is cracked, any tips? I try very hard to provide a customer service that is outstanding... There is nothing better than going to the mailbox to find your parts 2 days after paying for them...That's what I try to do...Ship the same day or next with priority mail...Even my international customers usually receive product within 10 days... Customer service is my top priority.. I treat everyone like I expect to be treated as a customer..Once an item is paid for I package as well as possible including industrial bubble wrap, and ship promptly. It's a simple thing to me..That's why 80% of my business is return customers. I don't sell junk, and I'm honest. Thanks for all the compliments! Pete    Report

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