Hi,

I would appreciate some expert opinions on my options. I have a HKS GT3037S turbo kit (turbo, manifold, wastegate, elbow etc) on my Evo RS. This issue as with most HKS manifolds is that they crack. The current manifold has been repaired before and has cracked again. I’m not sure if it is repairable or not at least without a lot of grinding down / prep work first. Maybe someone can advise?

I am not prepared to spend a grand on another HKS manifold as it’s likely to crack again, even with a turbo support brace. Unless someone corrects me otherwise I don’t think there is a stronger off-the-shelf replacement manifold that I can use – i.e. Ross Sport? I believe the turbo uses a T3 flange but I think the wastegate flange and routing pipe work from the wastegate to the elbow is unique to the HKS kit?

What are my options? Could I buy a new high-end manifold and have the wastegate flange welded on, but is the turbo position likely to be different etc? Is there a company that already provides a stronger manifold for this particular kit? Custom?

Much appreciated

Andy

 

i'd recommend a custom manifold, either in steam pipe or thick stainless steel.

On a side note, the americans hate those turbo's. So dont be surprised if you get flamed.

Maybe try the LancerRegister forums, as they are mainly UK based. I know Ross Sport posts on there. Send him a Private Message, should be able to point you in the right direction

Good luck!

 

I mean considering they obviously work so well- yeah we love them

To OP - check around with the vendors here to see who could help you out with regard to the manifold (whether or not it worth repairing or buying / building a new one) - ETS etc.


-Bink

 

I'd replace it with something NON-HKS their manifolds were obviously made of crappy metal so getting a new one will just result in another cracked manifold in the future. Was that one ever heat wrapped at one point? It looks like whoever tried to repair it tried mig welding it. Hard to tell from the pictures.

I'd contact ETS or shearer about getting a custom replacement one made up or us a local fabricator. Not being from the UK though I can only suggest places I know here.

 

it could have been repaired better. An experience TIG welding fabricator would know where to brace it and make multiple TIG passes on the the runners to strengthen them. HKS should have used thicker schedule 10 stainless. The current manifolds off the shelf will position the turbo differently. Not to mention the HKS turbos are T28 flanged i believe. They are not T3. You CAN have a fabricator make you a custom manifold by creating a jig for the HKS to insure proper positioning. This would run you anywhere from $600-$1000bucks depending on how the guy prices his work. If they use the right thickness and make quality double passes on the TIGs you should be perfectly fine.

 

first hand i've been a properly welded and braced HKS manifold (repaired) with the same turbo crack again.
Custom would be your best option IMO

 

i had hks turbokit >1yr without cracking, i had a few rod tig-welded from flange to flange(flange facing block and flange facing turbo), also, welded bracket on 02 housing to block, i believe it is 14mm bolt that screw on the block.
this way, you have all the support on the manifold, i had not had any crack on daily driving car.
i will post up some pics later if i can find it.

 

I had horrible experiance with the HKS manifold.


THis was the first one. Eventually the wastegate runner cracked completely off and was resting inbetween my radiator and manifold. I bought a replacement and after 100 miles this one cracks




I couldn't find another manifold that would work so I purchased a turbo kit from AMS. Thats not the cheapest solution but i wouldnt of went any other way.

Im just sharing the pain, sorry I don't have any helpful solutions to add to the thread

 

HKS turbo kit is not cheap either compare the AMS turbo kit.

It's really hard to believe that expensive HKS turbo kit come with cheap manifold.

 

i dont have to believe it, i've seen it first hand.
They crank. Especially when people dont use the supplied heat shields (to shop water splashing on it) and use heat wrap too. They just can't handle it.

 

^ Can full-race manifolds handle heatwrap?

 

pretty sure Geoff said they are fine, i know alot of race teams get their manifolds high temp coated and then heat wrap over the top of that, so that as soon as the car comes in they can start working on it

Gogo Geoff answers please

 

Appreciate the feedback. Its not a kit I would purchase by choice but it came with the car. Other than a poor quality manifold, what's wrong with the turbo itself?

I was hoping a fabricator would have identified a demand for this and fabricated a direct replacment for this particualar kit. I wonder if someone already has a jig for this from an earlier custom job?

Thanks

 

The GT3037 is a GREAT kit, but the manifold sucks!
A custom manifold is the solution.

 

custom would be nice but so hard to get t25 flange manifold to make.
key thing is you need bracket welded to o2 housing and bolt it to the stock block, just like how stock turbo/o2 housing is designed.
any tubular manifold will eventually crack without great support. turbo alone is like 20lbs and it's attached to down pipe and everything just pulls down, imagine the weight beeing pulled down on the tubular manifold...