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Old 03-27-2008, 05:22 PM   #1
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Default PEMs/Ceramic Coated Exhaust Manifolds

I'm getting a pair of exhaust manifolds from Andrew (haro), and they should be here any day now.

I want to go ahead and try porting them and cleaning them up, along with inspecting for cracks. If there'* any big cracks, I can weld them. Thing is, I have open access to an arc/stick welder for free through my gf'* grandpa. Can I use that if I discover any huge cracks? What about adding extra material around the outside edge of the inlet?

I looked for any tutorials on PEMs, didn't see a whole in detail but I did find a few helpful threads. As far as the cracks go, I want to go ahead and ceramic coat them. I saw back in '05, Wren did his with a ceramic based paint. How long did that last, and how was the turnout? I just want to make sure they're sealed up well.

Are there any decent tutorials for PEMs that I overlooked, and howbout the ceramic coating? I figured if I just look wren'* adventures, I'd find something of use lol.
- Josh

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Old 03-27-2008, 05:44 PM   #2
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No, you can't arc weld them. You need a TIG welder for the REAR to fix the cracks (or front/rear for the Series 1).

The front manifold is Cast Iron, so you need NICKEL rod to build up the 'necks' and you better be a very good welder to not have any voids. Criss-cross side by side beads, alternating directions each 'layer'. Then grind out to match the rears.

My coating has held up perfectly (although I did recoat them last winter when they were off the car, it was only to get the areas I couldn't hit while they were installed for the original coating test).

A couple others have used the same coating since me with success. To this day, mine look as good as the day I applied the coating. You CAN brush it on but I suggest you go to your local paint store for the little 'touchup' sprayer. Glass tube with a propellant cartridge. Works like a spray can.

And my original topic:

Last winter'* recoating:
(while repairing the crossover pipe advice is to remove the heatshields entirely for coating)
Click the image to open in full size.

Click the image to open in full size.

And what they looked like when the motor was pulled one full season later:

Click the image to open in full size.

Click the image to open in full size.

Click the image to open in full size.

I can get you shots of them as they sit in the car if you like. The shiny spots after recoating have baked to a uniform satin/flat finish, and there are no scratches anywhere, nor any flaking.

The test data in the topic above is still repeatable.
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