Exhaust manifolds and cracks....Solution? Thermosteel!

[Blaine B.]

Hey, recently found out about a product called Thermosteel. My friend used it on his Grandfather's XJ which had a hole big enough to pack this stuff into on his exhaust manifold.

After letting this stuff cure, it is rated to 2400 degrees farenheit, and actually increases strength the hotter the item it is applied to gets.

Its uses are for boilers, kilns, exhaust manifolds, grills, etc. I recently patched my exhaust manifold with this (hairline crack, small compared to his Grandfather's manifold crack) and it is holding!

He said he did it a few years ago and it is still holding as far as they know.

Definately worth a try if you don't want to mess replacing or welding your manifold. Best of all, you don't need to remove the manifold to do this!

http://www.kalimex.co.uk/section.htm...01.06.&pgid=21 (http://www.kalimex.co.uk/section.html?secpath=01.06.&pgid=21)

I bought this product at Advance Auto. Auto Zone is said to have it too. There were rumors that Ace Hardware and Walmart carried it, but neither did in my area....

Good luck!

[mcnamaag]

Took your advice and tried it last night. I will let you know how mine holds up but it appeares to have sealed fine and i had a BIG crack. LOL

[gjxj]

Thats some amazing stuff, room temp cure and good to 1300C.

"ThermoSteel is as good as a hot weld, without any of the hassle."

uh..

[Bender]

This stuff works well to pass an e-test or something where you need to plug the hole/crack temporarily for some reason.

In a couple weeks it will leak again.

[1985xjlaredo]

so which is it? It either works and lasts or it doesnt

[1985xjlaredo]

(http://www.kalimex.co.uk/section.html?secpath=01.06.&pgid=21)http://www.kalimex.co.uk/section.htm...01.06.&pgid=21 (http://www.kalimex.co.uk/section.html?secpath=01.06.&pgid=21)

I bought this product at Advance Auto. Auto Zone is said to have it too. There were rumors that Ace Hardware and Walmart carried it, but neither did in my area.... (http://www.kalimex.co.uk/section.html?secpath=01.06.&pgid=21)
The link says this in the Tech Data:Technical properties: Quiksteel is resistant to temperatures between -70ºC and +260ºC and, once cured, is impervious to most acids and solvents (including petrol and diesel).

[Blaine B.]

Says 1316'C

My friend used it on a hole big enough to pack this stuff into on his Dad's 94 XJ about 2 years ago and it is still holding.......so it's more than just temporary.

[Bender]

I think it's pretty cheap...give it a shot if you have a cracked manifold and if it holds you just saved yourself a lot of time and $$.

Usually stuff like this fails because it expands and contracts at a different rate than the steel or the bond between the steel and filler isn't strong enough for the application.

[Timber]

My only concern with their description is that it's "as good as a hot weld." The problem being that even properly welded stock manifolds don't seem to last.

[Blaine B.]

Depedns, I knew a guy with TJ and the weld has lasted about 3 years so far.

[Ed Kummel]

A cheaper method of fixing a cracked XJ exhaust manifold...
Take it to the dealer...most years prior to 2000 have a recall notice on this.
Ed

[Blaine B.]

Mine doesn't have that recall.

[BigG]

I, too have not seen a recall for the exhaust. There is a class action lawsuit out about that.

[gjxj]

The link says this in the Tech Data:Technical properties: Quiksteel is resistant to temperatures between -70ºC and +260ºC and, once cured, is impervious to most acids and solvents (including petrol and diesel).

The web site is buggered, the technical properties link takes you to the data for a different product.

[mcnamaag]

Mine seams to be holding fine but I dont plan on it being perm.

[TMXONR]

old thread, I know. But I just found it.


Would this stuff work if my header is cracked all the way around the joint?

[montanaman]

My only concern with their description is that it's "as good as a hot weld." The problem being that even properly welded stock manifolds don't seem to last.
I've got about about 12k miles on a weld that's still holding up well.

It had a hairline crack about halfway around the collector, and in between the tubes. I had it TIG welded for about ten bucks, but the TIG couldn't get in between the tubes. So I hit it with my oxy-acetylene torch, and brazed some flux and brass down into the middle. I also took the torch flame around the new weld area until it was red-hot.

That might be why it hasn't failed yet. The re-heat had the effect of "stress-relieving" the joint. Hopefully it will last.

[Blaine B.]

old thread, I know. But I just found it.


Would this stuff work if my header is cracked all the way around the joint?

I don't know, try it! I might apply more in the spring......but......

Right now I notice my exhaust manifold leaking when the vehicle is cold. When it warms up you don't notice it. So I guess the metal and/or the patching swells and fills small cracks and makes any noticable noise disappear?

I'm happy overall :) Easy and cheap.:looney:

[TMXONR]

Here is a pic of my crack.......

http://i22.photobucket.com/albums/b346/TMXONR/Jeep/DSC03742.jpg

[Blaine B.]

Wowwowwiwa! Nice crack. You could try it!

I know someone that patched their grandfather's XJ's manifold.....said it was large enough to pack in the thermosteel and it's alright up until this day.....

But this is a different type of crack that you have. The pipe can flex/shift I suppose.....where as the hole they had wasn't all around the pipe, so it really couldn't move as much.

Try it.....just mix it well and wait until spring (unless you have a garage that stays at a spring day temperature!) It's under 7.00 so it's worth a try. Just remove your airbox for better access or just tackle it and/or from below.....good luck!

[TMXONR]

What is the temperature that it is supposed to be applied at. It is supposed to be in the upper 60's this week. I guess I will try to find some this Tuesday.

[Blaine B.]

That should be fine.....50-70+ degrees I guess would be OK I suppose.

[TMXONR]

Hey guys I went and picked up some ThermoSteel at AutoZone today, and THIS STUFF REALLY WORKS!!!!!!!!!

As per directions, I cleaned the surface with a wire brush to get any loose stuff off. Then I mixed the ThermoSteel up real good, and put it over the crack. I tried brushing it on, but that proved extremely hard due to the tight space, so I used my finger to get the ThermoSteel on. I let it cure for about 4 hours, then went for a drive. First start up was Instaneous, but rough, It may be the computer getting used to the fix. After I drove around and got back home I restarted to see if it would start instantly again. Sadly it didn't, but HOLY CRAP It felt like it was healthy again. No more stumbling starts.

Here are a couple of videos showing the difference between cracked header, and The ThermoSteel repaired header.

Video with cracked header

http://i22.photobucket.com/albums/b346/TMXONR/Jeep/th_MOV02579.jpg (http://s22.photobucket.com/albums/b346/TMXONR/Jeep/?action=view&current=MOV02579.flv)

Video with ThermoSteel repaired header

http://i22.photobucket.com/albums/b346/TMXONR/Jeep/th_MOV03761.jpg (http://s22.photobucket.com/albums/b346/TMXONR/Jeep/?action=view&current=MOV03761.flv)

[Blaine B.]

Congrats, sounds MUCH better! Same with mine though, I can still hear something leaking. I did a seafoam treatment after repairing my crack and I still saw some smoke coming out from that region. It MAY be coming from where the downpipe connects up to the exhaust....I'll borrow a smoke machine some time and check it out this spring. It was dark out when I did the seafoam so I couldn't pinpoint the leak. Disconnect your battery for awhile to ensure it clears and learns the new quicker.

By the way do you have your efan on a toggle switch? Never heard one come on prior to starting the engine, at least with and XJ.

[TMXONR]

I can still hear something hissing, but I think it is comming from the back. The fan has always been like that, well as long as I have had it it has been like that.

[Blaine B.]

Well whatever, it sounds much better! Hopefully it will hold up, don't see why it shouldn't. Are all of your exhaust hangers, trans mount, and engine mounts alright?

[TMXONR]

Thanks! The drivers side mount looked kinda squished, but I couldn't really tell. It looks like where the exhaust is mounted to the bottom of the trans, the hanger is snapped clean. I'm not sure if it is a mount, or a piece of metal for a tag, but it is a clean break.

[Blaine B.]

Mine was snapped off of the exhaust in the same spot. I drilled a hole through the piece and then used some pipe tape (I think that's what you call it, the metal that is flexible and has a line of holes in it) and just tightly wound it wround the pipe and bolted it to the origional hanger. Cheap fix until I get a new exhaust.

[imwally]

I wish I would have seen this thread before I just bought a new manifold. It could have saved me some money so I could get new tires for it.

[Blaine B.]

Don't worry, it will happen again :)

[Blaine B.]

http://s20.photobucket.com/albums/b210/bbugaski/Videos/?action=view&current=JeepStart.flv

There's a clip of mine starting, today.....I don't have a "before application" video. I'll try to get another later so the wind/airplane aren't in the video, lol.

[groovyone]

I just tried this last night. It looks like it sealed the crack, but I must have another one. The noise got quieter, but did not go away. Time to check the rest of the welds.

[mcnamaag]

It took a little time but mine is leaking again. It lasted about 3 months.

[TMXONR]

Mine stumbled again the other day, then it started up regular with out stumbling. I redid it with some wire mesh, I might redo it again with putting header wrap around the ThermoSteel.

[Blaine B.]

Funny thing is as I was going to sleep last night I was reminding myself to post today and ask you how it was holding up.

Mine leaks when cold but when it warms up it quiets up alot. I do have another small leak somewhere else though.....but it's good enough. Way better than before.

[TMXONR]

Mine may have just been the cold weather too. Sunday when starting it up to load it on the trailer to go to Superlift it stumbled, but it was 25-30 degrees outside. A few miniutes ago when I moved it so I could wash all the mud and dirt of from the weekend, It started fine, it is about 60 degrees right now.

[Blaine B.]

I'm even talking in cold weather.......but until warm operating temperature. Perhaps the warmth the engine produces warms the exhaust manifold swelling the metal and thermosteel, which may seal any remaining leaks when operating temperature is achieved.