Stainless Steel exhaust manifolds

[miniCotulla]

Hello, I plan to buy this stainless steel exhaust manifold. Are these any good or prone to cracking?

Profidiesel Exhaust manifold

 

[scrambld]

Am I missing something, or is Darkside's DPF delete kit less than half the price of Rawtek's? Why is this the case?

So I'm looking at a DPF delete kit for my 2012 Jetta Sportwagen, and the two names I hear tossed around the most are Darkside Developments and Rawtek. Looking at the Rawtek kit, it's like $1200 (if I want to keep my catalytic converter, which I do). The Darkside equivalent is a shorter section...

forums.tdiclub.com

 

[lemoncurd]

it is a 304 manifold, it'll be fine. if youre worried about a stress fracture eventually then add a turbo support

 

[adamss24]

Hello, I plan to buy this stainless steel exhaust manifold. Are these any good or prone to cracking?

Profidiesel Exhaust manifold

As i remember you have a longitudinal engine vw Passat…on the profidiesel page it states that the manifold is for transverse engines…

 

[miniCotulla]

As i remember you have a longitudinal engine vw Passat…on the profidiesel page it states that the manifold is for transverse engines…

Yes, I know, we want to cut the flange and put a vband on there that it fits on my car/turbo.

 

[adamss24]

You're best bet its to make it yourself although i would rather use cast iron manifold with adapter plate then you can bolt a vee band if so you wish ! This way you can make sure your chosen turbo doesnt hit the chassis leg and gives you max clearance in the engine bay !

 

[miniCotulla]

You're best bet its to make it yourself although i would rather use cast iron manifold with adapter plate then you can bolt a vee band if so you wish ! This way you can make sure your chosen turbo doesnt hit the chassis leg and gives you max clearance in the engine bay !

I think this would be the most compact solution as the original manifold + adapter + 2260 already nearly hits the framerail. Those manifolds are already 20+ years old and also start to crack. Flow doesn't really seem great either

 

[adamss24]

Many exoerienced tuners from finland have no problem hitting 300+ bhp on stock cast iron manifolds.
Every log style one i made cracked due to stress in the material from welding. Tubular manifolds fare better because the material have room to expand. And these welded manifolds with pretty autogenous welds fare no better. I cannot remember how many stock bmw and t5/touareg manifolds i welded this year, on tuning forums everyone is replacing them with cast versions.

 

[miniCotulla]

Many exoerienced tuners from finland have no problem hitting 300+ bhp on stock cast iron manifolds.
Every log style one i made cracked due to stress in the material from welding. Tubular manifolds fare better because the material have room to expand. And these welded manifolds with pretty autogenous welds fare no better. I cannot remember how many stock bmw and t5/touareg manifolds i welded this year, on tuning forums everyone is replacing them with cast versions.

Maybe something lik this would be a better idea then?: https://spaturbousa.com/products/sp...f-jetta-b1-dasher-1-6-2-0-8v-1-9-tdi-tmw06t2l

 

[miniCotulla]

Many exoerienced tuners from finland have no problem hitting 300+ bhp on stock cast iron manifolds.
Every log style one i made cracked due to stress in the material from welding. Tubular manifolds fare better because the material have room to expand. And these welded manifolds with pretty autogenous welds fare no better. I cannot remember how many stock bmw and t5/touareg manifolds i welded this year, on tuning forums everyone is replacing them with cast versions.

Also wouldn't heat shielding prevent cracks from forming? I always thought the cracking was due to the manifolds cooling off to rapidly.

 

[miniCotulla]

Many exoerienced tuners from finland have no problem hitting 300+ bhp on stock cast iron manifolds.
Every log style one i made cracked due to stress in the material from welding. Tubular manifolds fare better because the material have room to expand. And these welded manifolds with pretty autogenous welds fare no better. I cannot remember how many stock bmw and t5/touareg manifolds i welded this year, on tuning forums everyone is replacing them with cast versions.

The 4 bolt style 1.6TD manifold also seems like it has higher flow then stock 1.9tdi: http://www.vanagondiesel.info/index.php?title=File:AAZ_Exhaust_Manifold_Comparison.jpg

 

[adamss24]

Maybe something lik this would be a better idea then?: https://spaturbousa.com/products/sp...f-jetta-b1-dasher-1-6-2-0-8v-1-9-tdi-tmw06t2l

Probably might work better however it’s taller than stock AWX/AVF/AFN manifold and it will definitely hit the chassis leg with it! I have made a longitudinal log style manifold to take a gtb226x vk onto a seat exeo (basically a b6/7 Audi A4) and it was very, very close to the chassis rail. I don’t even think the bmw f10 hot side with v band will be any better unless it puts the turbo a lot higher but that means you loose the air filter box !

 

[adamss24]

Also wouldn't heat shielding prevent cracks from forming? I always thought the cracking was due to the manifolds cooling off to rapidly.

I wouldn’t want to go much into metallurgy with you however the HAZ (heat affected zone) is always softer than the weld and if the metals don’t fuse properly coupled with pendulum effect of a heavy turbo sitting atop of a tdi engine which vibrates a lot on idle is the main issue there for metal fatigue ! I have a friend of mine that had issues even with expertly done manifolds from darkside (before they went for billet collector manifolds) and there is no exception ! The more joints you have in a pipe they more likely to fail at some point !

 

[miniCotulla]

I wouldn’t want to go much into metallurgy with you however the HAZ (heat affected zone) is always softer than the weld and if the metals don’t fuse properly coupled with pendulum effect of a heavy turbo sitting atop of a tdi engine which vibrates a lot on idle is the main issue there for metal fatigue ! I have a friend of mine that had issues even with expertly done manifolds from darkside (before they went for billet collector manifolds) and there is no exception ! The more joints you have in a pipe they more likely to fail at some point !

I think I will go with 1.6TD or even a gas 8v (can be bought new for relatively cheap) exhaust manifold and just weld an adapter for it.

I already created another thread here: https://forums.tdiclub.com/index.php?threads/8v-gasser-exhaust-manifolds.528490/#post-5801079