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Turbo Leaks

This is a public forum to discuss Eagle related technical issues. If you are having a problem with your Eagle, this is the place to find help.
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K4Eagle
Posts: 19
Joined: Mon Jul 25, 2022 12:01 pm
Bus Model: 1978 Model 5 Entertainer (Opaline), 1989 Model 15 Coach (Ron Burgundy)

Turbo Leaks

Post by K4Eagle »

Thanks to a white smoke cold start this winter, I noticed a leak coming from the exhaust manifold, which led to why the 6v92T was a little slow off the line.  A little welding repair and I'll probably break something else with restored HP.  Wish me luck!
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beltguy
Site Admin
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Posts: 2663
Joined: Wed Oct 08, 2008 4:39 am
FMCA #: F246286
Bus Model: 1985 Eagle 10 with Series 60 and Eaton AutoShift 10 speed transmission (SOLD)
Location: Evergreen, CO
Contact:

Re: Turbo Leaks

Post by beltguy »

Welding cast iron is a challenge.  There are several trains of thought as to how to make a satisfactorily/durable weld.  Some folks say that brazing is the only option.  Others have used special arc welding rod.  Yet others have used standard MIG process (mostly for non structural work).

An exhaust manifold complicates the issue even more because of the heat cycles.

Be sure to let us know how the repair was done.

Jim
Jim Shepherd
Evergreen, CO
'85 Eagle 10 with Series 60 & Eaton AutoShift 10 speed transmission SOLD
2005 Dodge 2500 with 5.9 Cummins and 6 speed manual 2022 Sunset 28 foot trailer
Bus Project pages: http://beltguy.com/Bus_Project/busproject.htm
Blog: https://beltguy.com/Travelogue/
Email: eaglesinternational.email at gmail.com   NOTE this email box is only for general correspondence related to the forum and not technical advice.  Technical questions will not receive a response.
davida
Posts: 184
Joined: Tue Jun 02, 2009 7:43 pm
Bus Model: 1985 Eagle 10

Re: Turbo Leaks

Post by davida »

I could hear the thud, thud, thud, of thinness on my street side exhaust bank with hammer taps years ago.  I was fortunate to find a good take off from some truck yard in Brownsville TX and replaced it.  I bet they are hard to find now.  Yes, please let us know how this works out.  Take lots of pictures.  There may be some ideas on you tube that someone has found.

David
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DoubleEagle
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Posts: 280
Joined: Wed Feb 14, 2018 9:26 pm
Bus Model: 1975 Model 05 Eagle
1982 Model 10 Eagle
1984 Model 10 Eagle
1994 Model 15-45 Eagle
Location: Dayton, Ohio

Re: Turbo Leaks

Post by DoubleEagle »

Unless you can find a good used one, take it to a welder that has experience with cast iron. It will need to be cleaned up, preheated, and welded with a nickel alloy rod, and then machined to a flat surface. No guarantees on how long it will last.
Walter
Dayton, Ohio
1975 Silvereagle Model 05, 8V71, 4 speed Spicer
1982 Eagle Model 10, 6V92, 5 speed Spicer
1984 Eagle Model 10, 6V92 w/Jacobs, Allison HT740
1994 Eagle Model 15-45, Series 60 w/Jacobs, Allison HT746
K4Eagle
Posts: 19
Joined: Mon Jul 25, 2022 12:01 pm
Bus Model: 1978 Model 5 Entertainer (Opaline), 1989 Model 15 Coach (Ron Burgundy)

Re: Turbo Leaks

Post by K4Eagle »

Some of you wanted an update.  I think I was lucky getting 55 rod to bond to the cast iron; it was amazing how fast the cast would vaporize, and I'd have to chase the growing pit with rod before it got worse.  Next, I discovered the mounting surface was rounded convexly; probably why the end broke in the first place.  Because of this, I decided to bronze the last port instead of grinding down any of the cast.  Will sand down to spec here soon.
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beltguy
Site Admin
Site Admin
Posts: 2663
Joined: Wed Oct 08, 2008 4:39 am
FMCA #: F246286
Bus Model: 1985 Eagle 10 with Series 60 and Eaton AutoShift 10 speed transmission (SOLD)
Location: Evergreen, CO
Contact:

Re: Turbo Leaks

Post by beltguy »

Thanks for the follow-up. 

I assume when you say 55 rod, you are referring to the special nickel rod such as:

Link to Amazon for Weldcote Nickel Rod

Jim
 
Jim Shepherd
Evergreen, CO
'85 Eagle 10 with Series 60 & Eaton AutoShift 10 speed transmission SOLD
2005 Dodge 2500 with 5.9 Cummins and 6 speed manual 2022 Sunset 28 foot trailer
Bus Project pages: http://beltguy.com/Bus_Project/busproject.htm
Blog: https://beltguy.com/Travelogue/
Email: eaglesinternational.email at gmail.com   NOTE this email box is only for general correspondence related to the forum and not technical advice.  Technical questions will not receive a response.
K4Eagle
Posts: 19
Joined: Mon Jul 25, 2022 12:01 pm
Bus Model: 1978 Model 5 Entertainer (Opaline), 1989 Model 15 Coach (Ron Burgundy)

Re: Turbo Leaks

Post by K4Eagle »

Yes Nickel/Iron rod.  I tried ARC at first but switched over to TIG because I felt I had more control (and it was my first time trying ARC).
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DoubleEagle
Club Member
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Posts: 280
Joined: Wed Feb 14, 2018 9:26 pm
Bus Model: 1975 Model 05 Eagle
1982 Model 10 Eagle
1984 Model 10 Eagle
1994 Model 15-45 Eagle
Location: Dayton, Ohio

Re: Turbo Leaks

Post by DoubleEagle »

And did you preheat the cast iron to 350 degrees or a little more?
Walter
Dayton, Ohio
1975 Silvereagle Model 05, 8V71, 4 speed Spicer
1982 Eagle Model 10, 6V92, 5 speed Spicer
1984 Eagle Model 10, 6V92 w/Jacobs, Allison HT740
1994 Eagle Model 15-45, Series 60 w/Jacobs, Allison HT746
K4Eagle
Posts: 19
Joined: Mon Jul 25, 2022 12:01 pm
Bus Model: 1978 Model 5 Entertainer (Opaline), 1989 Model 15 Coach (Ron Burgundy)

Re: Turbo Leaks

Post by K4Eagle »

yep.  No pops while cooling.  it was a relatively small area, and there was a good amount of meat to work with.  By contrast, my 78 with a 8v71 had paper-thin manifolds and we ended up having to find a replacement.
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