I've got a medium sized crack in both my front and rear exhaust maniofolds. I'd like to get this done properly, but new GM parts seem outrageously priced. I'm considering drilling the crack ends, bevelling the cracks and then welding them in place. I should be able to get to both cracks. Is ECU/electrical damage a real problem? From reading previous posts, I think I have stainless manifolds. Does this type of repair weld usually last? Am I headed in the right direction?

Well Im pretty sure that all of the 3.8 manifolds are a rust color so if you call that stainless then I guess its stainless.

does your 92 have an EGR valve, if so you can just get a set of used manifolds 93-94 bonnes some other H-bodies used the series one on 95, if you dont have a EGR then you are restricted to a set of main'* off of a 92.

any H-body 92-95 should work for you except the 95 bonne

confused yet??

These look like partial tubular manifolds that have been welded together. They don't look like cast iron. But you are right, they look rust color to me. Do you believe a 92 SSE has stainless manifolds?

I don't think I have EGR. I checked the date of manufacture, it'* 10/91. Do I have any other options from earlieryears?

How'* your luck with using used manifolds? Do used manifolds tend to fail quickly? Is welding a real option or just a short term fix?

Do you have a mushroom looking thing just forward of your throttle body? Ported into the upper intake and front manifold? In my signature picture, it'* the thingy with the pontiac logo on it (your cover would be plain black if you have it) If so, you have the EGR. If not, you don't, and you need 92 only manifolds (not from an SSEi either), or you can weld over the EGR port on used manifolds.

I've never seen a crack in the tubular manifolds yet. I would be tempted to weld in place in your situation, but disconnect your battery and PCM entirely before welding. I'm betting you have no EGR (which keeps combustion temps down), as this may have caused the cracks.

The best wrecker solution would be to get manifolds from an 95 SSEi (these wouild be the 'newest' that would fit) and weld over the EGR port.

There'* no mushroom shaped thing. The in place welding solution would certainly save some headache. Most of what I know has come from reading some of your previous posts. Have you had good long-term outcomes welding? Any other electrical items to disconnect other than PCM and battery? I have the tubular manifold and they have cracks. However, it'* good to know it doesn't happen frequently. If I can weld over the EGR port, what other years/models could work?

Are these 92 SSE manifolds stainless steel?

I don't know if they're stainless, the exhaust pipe is, but not sure about the manifolds, they dont' look like it....

If you do get a newer set of manifolds, you could also just grab the EGR for them, and not hook it up to anything. :?