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[Andy B]

I wouldn't bother with the M6 holes, just get it all nice & hot before you weld it, and then make sure you get an nice even weld on/over the crack. In that position you don't need to prep either ie grind a V into the cracked bit.


A 'new' manifold would be easier though!      

No doubt, but a new car would be even MORE convenient..
Nothing but troubles with this piece of junk...

I was thinking of heating the material to approx 60degrees celsius, but is seems like others advice even more.. Perhaps I should go for 100degrees celsius...

You think I can weld it all in one piece or will this make the material drag against the welding point?

I'd be heating it with oxyacetylene to a dull red!   If not i think you'l find it'll crack along side your weld if you don't get it really really hot.

[Shagma]

thanks.. got i welded by a friend. he told me he had to weld an inch at a time, and hammer the weld flat immediately after welding. otherwise the weld will retract faster than the iron cast material, and cause the material to crack..
the crack was really long, much longer than i expected... but I'm looking forward to check it for tightnes during operation:)
best of all, it only costed me 20pounds...

[Seth]

apparently you need to preheat cast iron before you weld it and as soon as you have welded it you need to wrap it in insulation so that it cools slowly otherwise it will crack if it cools to quickly

Sounds right this.
But, what about trying fire clay in the split first. Available from plumbers merchants/DIY centres etc. Got to be worth an inexpensive try!