Inlet manifold servo take off thread damaged.
Turbo Mini Forums

Well i brought a metro turbo inlet manifold the other day and i had a good look at it today and the thread the servo take off banjo bolts to is damaged.

Im not sure how its been damaged, but there isnt any of the threads left.

Whats the best way to repair this?

I did think about drilling it out and tapping a new thread, but i dont have a tap that big, also it would mean i would need to get some new servo pipes made up with a larger banjo fitting...

Any advice would be great, if not ill have to just search for another inlet :(

Can you make an alloy boss with the correct thread and weld it in?

I seriously doubt it!

Sounds like a good idea, but iv not got anything that i can weld ali with, iv only got a mig...

Might work with chemical metal though at its not under any stress...

Out of interest will a N/A inlet manifold for a Hif44 fit with the turbo exhaust manifold?

The flanges are different thickness so you would have trouble bolting the manifolds down

Apart from that flanges being different thicknesses, does the manifold physically fit about the turbo manifold?

As it will be easier for me to cut some washers in half and weld them to a washer so the manifold faces are brought up to the same level, if that makes sense?

Like this?

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got it in my head that a n/a manifold wont fit above the turbo exhaust manifold....

And on the 7th day........... God created turbochargers!

Even if it does fit (not sure) you would have to modify the bolt "half" holes as well as making the stepped washers.

The N/A inlet has basic half holes (ie, C shaped) so has to slide over all the studs from the back.

The Turbo inlet has upside down J shaped holes/slots so it can slide down from above without having to be fed over the studs, look at yours and you will see what I mean.

Edited by Rod S on 28th Nov, 2009.

Schrödinger's cat - so which one am I ???

Thanks for the information Rod.

In that case, does anyone know what thread type the banjo bolt should be so i can buy the correct tap?

Means i get to have a play on my lathe anyway.

Araldite it in.... sorted.

1293 Turbo mini

Has anyone every used this stuff

http://cgi.ebay.co.uk/Laser-4707-Aluminium...=item414a2edf55

Im just thinking if iv got to find a way to secure this in place if this stuff is any good then ill give it a go at securing a DV take-off aswell...

If not ill just go with araldite or chemical metal.

i would of sad that it is a load of sh*t because you are going to lay the metal on the maniford and you will still need to tap it out a coil kit is about £30

1293 Turbo mini

Ah sorry i must have been writing my post when you posted.

Iv just done a quick google search and heli coiling looks like an alot better option and more cost effective. I dont know why iv never heard or seen them before.

Thanks for showing me about those, look like they could save loads of time for loads of things.

Helicoils are a good solution but 95% of the cost is in the special tap and the fitting tool, the actual inserts are cheap.

So as a "one off" fix you might be better finding an engineering shop that has that size tap/tool so you would only be paying for the insert and their time.

I would guess that up at that size (5/8" UNF from memory) a kit (ie, special tap, fitting tool and one or more inserts) would be more than the cost of a secondhand manifold....

Last kit I bought was for 5/16" UNC to do several stud holes on an alloy cylinder head and even at that small size, the kit was nearly £30.

But prices may have come down since then......

Schrödinger's cat - so which one am I ???

it's defintately a similar size to the crank thread as i used to plug my inlet with an old pulley bolt.

Dont you know a local engineering shop? Take it to them and basically "Ask" someone can fix it

1/4 Mile 14.3secs 96Mph Terminal 10psi of boost.


Fibreglass Parts? - http://www.tdkracing.co.uk/
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You can mig ali on your DIY Mig machine if you change the wire over to ali (about £15 for a small 0.8mm roll from Hallfords) and use pure argon (again, Halfords, about £8).

You need to pre heat the manifold if you're gonna weld in an ali plug which you can then re-drill and tap. Kitchen oven to 300 C is ok but gentle heat from a butane torch is better as long as you heat gently and evenly. Need to then weld quick before cooling. You can do it with a Mig but it requires abit more skill and patience than blasting a piece of steel bodywork.

Personally, for about £15 from fleabay, I'd buy another unless the repair you're doing is going to be safe enough to torque the servo take off banjo bolt back up again.

Whatever repair you do, if it lets go, you might not have enough pedal force to stop the car.

Richard.

Minivanless, but reluctantly happy living with the decision. There'll be another one day.
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