Another Cracked Exhaust Manifold Victim

:
2003.5 Mazdaspeed Protege
Well, in the process of preparing for installing the Corksport downpipes, I've discovered my exhaust manifold is cracked. Took off the heat shield tonight and found each crotch of the manifold cracked, with the largest in the middle. To boot, I found that the far left lower manifold bolt is missing.

I suspected it might be since last week, by the recent 'pifffing' sound when starting the engine. I checked the manifold last October and it was okay then, but now some 10K miles later-NOT!

I figure my options are:
a.) try welding the cracks
b.) replace with OEM manifold
c.) install an aftermarket manifold

My questions are:
i.) has anyone successfully welded a crack manifold without it cracking again?
ii.) why replace with expensive OEM that will crack again in the future?
iii.) does anyone have good leads to aftermarket manifold that will fit MSP?

Thanks in advance for any responses and leads.
 
Cast parts can be welded with a special rod and the part must be heated before welding and cooled slowly after the weld is made . Find a good welder and get them to do the job. By the way it wont be cheap to do ,you would be better off getting an aftermarket manifold
 
macklum said:
Cast parts can be welded with a special rod and the part must be heated before welding and cooled slowly after the weld is made . Find a good welder and get them to do the job. By the way it wont be cheap to do ,you would be better off getting an aftermarket manifold


Thanks for the reply.
The only aftermarket manifold I'm aware of is MAM's for something like $1200.
I can afford that. Do you know of any others?
 
I take it that you're out of warranty? That happend to mine about 3 months ago and I had it replaced under warranty. Even if you want to upgrade, at the very least, get the replacement through the warranty (if you can) and sell it to help offset the cost of the upgrade.
 
Kokopellian said:
I take it that you're out of warranty? That happend to mine about 3 months ago and I had it replaced under warranty. Even if you want to upgrade, at the very least, get the replacement through the warranty (if you can) and sell it to help offset the cost of the upgrade.

Very good idea about the OEM replacement sale to offset cost, but I doubt my dealer with cooperate since I'm over 70K because of my daily commute. I'll call to see how far I can get.
 
Alejo_NIN said:
also, please check the WGA, since they seem to go hand in hand went going PLUFFF

My boost gauge does not indicate any WGA issues, it builds to 6 psi right away thru the normal RPM range, however, it doesn't seem to pull very until its over 5000 RPM.
 

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