Soon after my car was boosted the manifold i had put on cracked, so i decided to just replace it completely. I found this guy online who said that it wouldnt be a problem to make me one that is a dirrect fit if i simply sent him my old one. Well after waiting 3 weeks longer than he told me it would take, i got the manifold. It turned out that it didnt fit all the way (turbo touching the fan) but me being impatient found a way to stick it in after unbolting my downpipe from its hangers. Now when i was taking off my turbo again two front bolt heads snapped off and im stuck with two bolts broken in my turbo and a massive exhaust leak.

Im sitting here wondering where to take this car. Should I go to a regular repair shop or somewhat more of a specialty place? And if the bolts broke, does that mean there was too much tension and i need to get my manifold redone or if i take it to a shop they could make it fit without that?

I live in the Chicago NW suburbs, and i already called AMS but when i heard their prices and that they are all booked for the entire summer that quickly killed the idea.

I would appreciate any help and ideas.

Reverse thread taps?
Getting some of the manifold to head flange and manifold to turbo flange decked?

You have one of the biggest 2GNT communties in the country up in your area. Post in the announcements/GB forum and offer to buy food and drink if people can come help you out. Doesn't seem like it would be too much trouble to repair things enough to get you on the road. Shit, come to think of it, you could call up ERT too. :shrug

Never give up the fight.

Originally posted by gotboost2394
Soon after my car was boosted the manifold i had put on cracked, so i decided to just replace it completely. I found this guy online who said that it wouldnt be a problem to make me one that is a dirrect fit if i simply sent him my old one. Well after waiting 3 weeks longer than he told me it would take, i got the manifold.

Don't mind me, I'm breaking this post into pieces because that top paragraph is unclefucking long, and consequently hard to read. This top part is irrelevant.

Originally posted by gotboost2394
It turned out that it didnt fit all the way (turbo touching the fan) but me being impatient found a way to stick it in after unbolting my downpipe from its hangers.

This is only relevant if it is what caused your bolt troubles. I don't believe that it is.

Originally posted by gotboost2394
Now when i was taking off my turbo again two front bolt heads snapped off and im stuck with two bolts broken in my turbo and a massive exhaust leak. Im sitting here wondering where to take this car.

Ah, the meat of the post. The broken bolts are in the exhaust housing of the turbo? That is a difficult place for a bolt to live. The heat cycles that the bolt and housing encounter really make breaking those very easy.

I would bring the turbo to a machinist and have them drilled out and re-tapped.

If you would rather do it yourself, put a pipe wrench on however much of the bolt that you can get. PB Blaster is your friend! If you can't get it out this way, drill into the bolt, and try an easy-out. If this doesn't work, drill it out, and helicoil it.

When you get it back together, don't re-use bolts, just get new bolts, of the highest grade that you can find, and coat the threads generously with nickle anti-seize. Don't use the cheap shit, the nickle anti-seize is good to 2200* F.

Originally posted by gotboost2394
Should I go to a regular repair shop or somewhat more of a specialty place? And if the bolts broke, does that mean there was too much tension and i need to get my manifold redone or if i take it to a shop they could make it fit without that? I live in the Chicago NW suburbs, and i already called AMS but when i heard their prices and that they are all booked for the entire summer that quickly killed the idea. I would appreciate any help and ideas.

As I said, have a machinist pull the bolts, and find anybody who is good with a welder to touch up whatever still needs touching up. Exile Racing Technologies is near you. Give them a shot if you can't get this taken care of by yourself.

Well i'd want to take it somewhere since pulling my turbo would be a huge pain in the ass. It seems that the bolt broke because of the angle of the manifold to turbo flange, because it was a really tight fit. When i tried taking them out again, no luck.

I already tried drilling it out on my own and broke about five-thousand drill bits, im just getting sick of this whole manifold issue, i saved money on getting it made, so i guess i'll just put that to getting it in correctly.

ERT is kind of far from me, and i dont like driving the car in this shape. My buddy recomended this place called ATA near me, he said they do all kinds of work and they do a good job. I went over there and the guy said he could do it for about $200, and if needed change the flange angle of my manifold.

Would it be in your budget to get a couple of SPAL fans? Maybe a pusher configuration, rather than a puller?

Originally posted by Ducking_Fumbass
Would it be in your budget to get a couple of SPAL fans? Maybe a pusher configuration, rather than a puller?

WOW, why has the first time I even thought of such an OBVIOUS solution? my master plan fitment issues=gone

I've snapped off many, many bolts in my exhaust housing. Any time I ever had to unbolt my downpipe i broke at least one bolt off.

Drill it out with a cobalt bit, clean the threads up with a tap, buy a v-band adapter from ATP and never worry about it again.

You didn't happen to buy this manifold for Forced Air Inc. Did you?