The saga of my Fiero rebuild continues...

I was planning on doing my brakes today so I can get my Fiero inspected and on the road, so I can take it back to the engine builders and have them fix the leaking rear seal. I started the engine early this morning while it was still dark in my garage and thought that it sounded differently than usual. So I did some looking. In the process, I manually operated the throttle by hand while listening to the engine. When I did, out of the corner of my eye, I thought I saw some flame. So I did it again and sure enough. See the photo below. I could see it along the exhaust on cylinder #6. I got my trouble light and took it over to the spot and from the picture below, you can see what happened. The exhaust manifold cracked along the weld.

A used manifold costs 350 dollars from the Fiero factory. Not a problem, but I don't like spending that kind of money for a used manifold. The rear one is 250 dollars. Anyone in here have a set of old manifolds for an '88 GT they'd like to sell me?

Has anyone ever had one re-welded and had any success with it? This is getting frustrating. I am thinking no more mid-engine or front-wheel drive projects for me. Front engine, rear-wheel or four-wheel drive projects or motorcycles, all pre-smog for me anymore.

[This message has been edited by eti engineer (edited 10-26-2021).]

quote Originally posted by Xenoblast: Yes, also id port the headers to gain 8hp while your at it. heres what mine looked like: The process isnt terrible, I could have done it in a weekend if i had all the parts right away, with the header welded soon after, and if 2 studs werent seized.

What am I looking at in your photo? I think the piece I need to see is out of the top part of the picture. I am just hoping I can pull the exhaust manifold with the engine in place. It appears that I can. I think there is enough room between the firewall and the engine. If anything, I think maybe I can undo the dogbone and pull the top of the engine back a little to give me some more room. I sure thought that I would have the car back on the road by the end of this week with all work done. Oh well....

Oh, I see. The blue tube is the one that goes to the fresh air intake, right? The totally cracked portion is your exhaust manifold? What a mess!!!

[This message has been edited by eti engineer (edited 10-27-2021).]

[This message has been edited by cvxjet (edited 10-26-2021).]

quote Originally posted by eti engineer: What am I looking at in your photo?

That is (or was) my crack in my headers. You asked if welding cracked headers works, it has worked for me for like 3k miles now. We will see how long it lasts, but I now live in a less rainy state so it shouldnt crack any time soon.

Heres a picture of them out, probably should have sent this first.


Also I pulled them off with the engine in the frame, just need small hands and hope that no studs are siezed

[This message has been edited by Xenoblast (edited 10-26-2021).]

[This message has been edited by eti engineer (edited 10-27-2021).]