[Shop-talk] Ancient furnace with cracked manifold

[Jack Brooks]

It needs to be replaced, but in the interim an important question is whether the crack closes up when it gets hot.  I had a split manifold on a car that was not visible.  I could clearly hear it when cold, but closed up as the manifold heated up and expanded.  When it was finally replace, the crack was clearly visible.

This, being and older home, is likely somewhat drafty.  This is not bad right now.  Regardless, if they continue to use it, additional CO monitors would definitely be a good idea.

I suspect high temp goo might work out, but prepare for the worst.

Jack

From: Shop-talk <shop-talk-bounces at autox.team.net> On Behalf Of Jim Stone
Sent: Monday, November 8, 2021 8:18 AM
To: Pat Horne <patintexas at icloud.com>
Cc: Shop Talk <shop-talk at autox.team.net>
Subject: Re: [Shop-talk] Ancient furnace with cracked manifold

Thanks, Pat.  You are correct that a replacement is unavailable.  The furnace is just too old.  As for having it welded, I should add that my brother-in-law - who lives nearby and is an engineer with tons of local trade contacts - looked at it and concluded that trying to remove it for welding was not a good option.  Surprisingly, he did not tell her to replace the system immediately, which was surprising as he is someone who generally errs on the side of caution in matters like this.  It has been a while since he looked at it (they have owned if for a year but not lived in it do to other extensive renovations) but I will also call him to discuss it.


On Nov 8, 2021, at 11:05 AM, Pat Horne <patintexas at icloud.com<mailto:patintexas at icloud.com>> wrote:

Jim, you hit on most of what I was thinking. At a MINIMUM I’d add a second CO detector.

I assume a replacement manifold is unavailable. You might take your photos around to some welders to get their opinions & prices.

The cost of repairs or replacement are nowhere as dear as losing someone to a faulty furnace.

Peace,
Pat
Pat Horne
We support Habitat for Humanity


On Nov 8, 2021, at 9:58 AM, Jim Stone <1789alpine at gmail.com<mailto:1789alpine at gmail.com>> wrote:
My daughter and her boyfriend have bought a turn of the century house with an ancient coal-fired furnace that was long ago converted to natural gas.  It works fine and they’d like to put off replacing it for as long as possible while they invest their money in other parts of the house.  However, the furnace has a cast iron exhaust manifold that is cracked pretty badly and it scares the hell out of me.  Following are some screenshots from a video she sent me, starting with the overall exhaust.

<Screen Shot 2021-11-08 at 10.19.11 AM.png>

You can see the top of the manifold in the lower right.  Here is a side view:

<Screen Shot 2021-11-08 at 10.12.34 AM.png>

The orange goop was applied by a furnace tech they hired, who said he really shouldn’t have touched it at all but did what he could.l. However, here is a shot just below the goop:

<Screen Shot 2021-11-08 at 10.13.09 AM.png>

And, a shot from the other side:

<Screen Shot 2021-11-08 at 10.27.00 AM.png>

As you can see - assuming the photos come through - the manifold is totally shot, although it feels solid and doesn’t appear to be in danger of falling off.  In theory, it could be removed and taken someplace that does cast iron welding, but I suspect that would be a royal pain and not guaranteed to succeed.  She has a CO2 detector in the basement, but I will be visiting her next week and want to try to do more.  “More” might be trying to convince them to bite the bullet and replace the system immediately, but I have also thought about treating it like an automotive exhaust system and trying to patch it to get them by for a season or two.  What are the group's thoughts on something like JB Weld High Heat putty (https://www.amazon.com/J-B-Weld-8297-HighHeat-Degree/dp/B007PP26RI/ref=pd_bxgy_2/138-6104268-8394138?pd_rd_w=nQ3PU&pf_rd_p=c64372fa-c41c-422e-990d-9e034f73989b&pf_rd_r=2F076DNFFJBZ1G9PK3TY&pd_rd_r=623d1e00-f712-4380-897c-474fe9ee6337&pd_rd_wg=1YSqH&pd_rd_i=B007PP26RI&psc=1) and/or their high heat wrap (https://www.amazon.com/dp/B00N582CBY/ref=emc_b_5_t)?

Thanks,
Jim (and Sara)




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