well my setup had beening hitting full spool by 3800 and yesturday i noticed its not until about 4500 or so. so today i checked all the bolts and they were all tight/no issues. so i started it and ran my hand behind the manifold and felt air flowing in one spot so i shut it off and ran my fingers around and felt a good 1 inch long crack that i could put my finger nail through. this really sucks because i dont wanna pull everything back off the car to fix one little thing and then having to replace every damn gasket from the mani back. and its gotta be done in 1 week because ill be leaving for a different post.

so being where the crack is do you guys thinks its possible to fix it without taking the manifold off the car?

 

You can grind that down some and then reweld, but don't count me being right.

 

If you want it fixed CORRECTLY, take it off.
Something caused the crack, any ideas?

 

hummm nope. the other day a nut came off one of the bolts holding the wastegate on and i drove it home because it was hot enough it was still sealed and i didnt know about it. but im thinking maybe it might have been a bad weld in that spot.

 

what manifold is that??? i just plain dont like the design of it, the pipe heading up to the turbo has a lot of stress on it. it would be a better design to have the flange welded basicly to the manifold instead of extending it that far up. its not a bad weld, its just that the pipe broke because of the stress on it.

to fix it propererly you need to pull it off and have it tig welded back together. i myself would add some gussets to support that tube better. id also look into making some braces to go from the turbo to the block to help support the weight of the turbo hanging off that manifold.

 

QFT

Who's manifold is that, we have saw it before, but looks like the design is poor (how the turbo flange hangs on the manifold).... As stated above.

You really need to pull it off and TIG weld it, to fix it right.

 

its zzp manifold. and i havent heard of anyone elses cracking so maybe i just got a bad one.

 

Have you contacted them, I am sure they will warranty it?

 

no its sunday and i just noticed it today. yeah im sure they will too but i dont have time to send it to them and wait to get it back. i am in the middle of a pcs move to another military post. zzp is an awesome vendor and by no means should anyone take this thread as a value of their quality. everyone one has a bad piece in a product from time to time. i just happen to get this one and the crack is worse its about 1 1/2 - 2 inches long. ill try to get a pic.

 

If it's our manifold, it may be an early design and we'll take care of the issue with an updated design no charge to you. Please email cust service and we'll get right on it.

 

thanks guys ill be sending you an email in about 20 minutes and this is just another proof of how awesome you guys are quality wise and customer servise wise. and this is another reason why people SHOULD NEVER BASH VENDORS. anyways thanks guys

 

Exactly as long as you contact vendors they should be able to resove the issue. The worst thing that a customer can do is to post a complaint before they even let the manufacture know. They cant read minds to know that something happened

 

well i got the turbo manifold off today and holy f**k its f*cK*d up.





man and zzp said i have to send them my manifold to get a new one and i cant afford the down time so i guess ima have to pay someone to tig it somewhere around here. and decide where a good support rod might need to go. any ideas?

 

design flaw's = this.

looks like thin wall SS at that...yuck.

it also looks like you have an exhasut leak at the head as well, that'll cause spool problems.

unless you remedy this design issue, this will keep happening.

weld in a nice support beam from the flange to a bracket you'll have to make on the engine.

there are plenty of ways and spots to use in order to pull this off.


get to work, good luck.

 

yeah the one from the head was a bolt i forgot to tighten down the rest of the way in the beginning. im kinda irratated it only took about 500 miles for this to happen though but all things will work out hopefully in the end.

 

duct tape will wokr

 

lol if you cant duck it.........................






















get a new one

 

We have changes implimented that should be done to yours. If you return it, we'll ship it back same day. I'd rather have it back to ensure it's done correctly. Based on the pictures, it may have to be replaced altogether which would be covered under warranty if that's the case.

 

I'd have to agree.... Need to run heavier wall tubing,and weld that flange to it without that extension piece. hell that pos ebay manifold I cut up laster 15k and is still rockin, going on ranger's car soon.

 

things is i cant afford to have a different manifold right now. i dont have the time/money to rework the downpipe and what not. and i cant afford downtime of the car.

 

If you send it next day, and have it sent back next day, thats only 4 days return time.

 

naw im just gonna have my guys fix it and put a brace around the neck part and make some kind of brace from the engine to the turbo and when taxes come in get the vulcan long tube turbo manifold and intake at the same time.

 

Might be worth the lil extra down time to send it to ZZP... then you get a new piece without the design flaws and it's still warranteed.. I Imagine if you go to welding on this one, and it breaks again, they won't be as eager to replace it.

 

well then if it breaks again i guess ill be ordering the vulcan long tube sooner than expected

 

I talked to the guys in fab and they said that a few improvements have been made. Compared to your piece, the new one has less welds. The welds are thicker and there are support bars. To bring yours to spec we would have to add the support bars and go over all the welds. I would prefer to replace yours with a new one though.

here's a pic

If you ship it back NDA and we return a new one NDA, you'll be down less than 48hrs. Or you can pay for the new one and we'll refund you when we get the old one back as I suggested in the email I sent you.