We are at a rest area and are good for the night if needed and we do have a toad. I noticed for a pretty good ways that I was making more smoke than usual so we pulled in at the rest area to check it out. The exhaust pipe broke at the welds at a 90 and at a flange. The turbo was only getting exhaust from one side of the engine. The other side exhaust was open into the engine bay. I unclamped the pieces and have them off. I just need help finding someone who I can take the parts to to have them welded. Does anyone happen to know someone in the area? We are just north of Memphis, TX. That is probably the closest decent size town. Otherwise, we are 75 miles south of Amarillo on US-287.
Also, the "not gen" light came on a few miles back. Hopefully that won't run into anything. I do have the wiring diagrams with me, and can probably troubleshoot that one pretty easy (hopefully).
Thanks for any help!
Mike
You may want to consider replacing the pieces because the failed area (the crack line) will likely not hold well depending upon the failure mode. If the area failed due to high-cycle fatigue then the metal in the crack zone will be less likely to hold a weld and will soon open up again initiating from microscopic cracks. If the failure was due to thinning of the material then it will be very hard to weld. If the failure was due to creep rupture then the grain boundaries will be opened up and will continue to fail unless the grain boundaries are healed via solution treatment (might as well replace). You may be able to get a weld to hold to get you out of trouble but don't expect it to be a long term fix. Replace the pipe as soon as you can.
I wish I knew someone in the area there to help you but I do not.
I found a welder. I'm headed to take him the parts. I'll let you know how it works out.
Mike
Welding on the 6V92 merge pipe usually will lead to MORE expensive repairs.
When the "Y" crack along the new weld joint you will have metal migrating into the turbochargers turbine wheel.
Most of the fittings and "Y"'s are rotted and rusted thin as Greg has mentioned.
I don't wish the FOD damage on you, but the odd's are against you. If you can secure a new fittings you will "save" yourself some dollars.
Welding on "pre" turbo exhaust piping keeps me employed. Welding on new metal is different situation.
Possible option: Call NIMCO (http://www.nimcobus.com/) and see if they can next day air you a good part. I agree with the others that welding will be a temp fix at best. Welds will make the parent metal brittle and you will be chasing cracks if there is much stress. I wouldn't want to risk a turbo.
Let the welder fix your pipe if you are worried about it Industrial Diesel 8705 Harmon Rd in Ft Worth will have the pipes new and used
good luck
The piping isn't factory I don't think. The turbo is on the side of the motor. The joints were brazed. The welder brazed it back together. Yes, the pipe is brittle and thin. But, at this point I have no choice but to put it on and run it. If I was at least in an RV park, I might could wait til Monday and find a muffler shop and have them fab me a new piece. But that's not the case. We are in a roadside rest area running the generator. At this point, I'm not sure that we should continue our trip. We are a third of the way there. We were headed to Yellowstone. Now, I'm considering limping back home. I am so discouraged. If that piece is thin and brittle, how bad is the rest. I'm thinking "wouldn't it be silly to chance the run to Montana?". Anyway, I'm going to bed, gonna get up early and put the exhaust back together and maybe then I'll think clearer and know what to do.
Good night. Thanks for the advise.
Mike
Do you have a 8v71 with the side mounted turbo you can get the pipe made in Amarillo there is a large truck muffler shop there I am betting it won't give you any more problems on your trip even on factory pipes on that setup are welded never heard of not welding a pipe I weld flares on the ends all the time you buy those from Napa for that purpose.Enjoy your vacation don't let that stop you
good luck
luvrbus, It's a 6v92 with a side mount turbo.
Still the same Mike not a show stopper drive in on to Amarillo and check it you can tell if it is starting to break
good luck
Mike,
Is your generator belt driven ? Just wondeing why the gen Light came on ? Just coincidence, not probable ?
Best of luck with the weld job. I feel for you with this happening 1/3 into your trip. You wull use your best judgement.
As a pilot I have been delayed / cancelled many times. It is always better being down here wishing I was up there....as opposed to....
Good Luck to you,
Gary
Part of owning on older bus is the odds and ends that need attention no matter how hard one tries to anticipate breakdowns. . I'm with luvrbus and sure wouldn't let something like that stop your trip. I would get your pipe made as early as possible and while your their have them check the other side. Not a big fan of brazing. It is very soft to start with and adding exhaust heat will only make it worse. Make em weld the new one.
The flanges and 90 should go over the pipe never the same size butted up to the pipe and welded then it will last longer without breaking at the weld fwiw
Don't cancel your trip. When I travel I realize that things happen and I might have to modify the schedule a bit for repairs. These things are a part of traveling, no matter how much planning and prevention you attempt. I made several roadside repairs through the Rockies (mostly Jake brake wiring), with one repair being an exhaust patch. Still had a great time, and you will also if you keep going.
I was called to dinner and didn't get to finish my thoughts. If I had to on my trip, I was willing to park the bus, rent a car and stay in motels, then retrieve the bus later. Your bus is a tool to have great experiences with. If that tool breaks you sometimes have to use another even if it is not ones idea of a perfect way to do it. Don't ever let a crippled bus get in the way of making good memories. Ten years from now what "travel tool" you used will be unimportant. Don't put off today what you might not get a chance to do tomorrow. Another tip: Buy each child a flip video and let them do their thing. I took a photography class in college and I didn't do as good a job as the kids did. They caught more candid moments and behind the scenes shots that are way more interesting than anything I could have ever dreamed of doing (Hard to get the good stuff when your hands are on the steering wheel). They are the Facebook and Youtube generation and have developed incredible skills at capturing great moments.
While in Amarillo stop and see Cadillac Ranch. My kids loved it and it is directly beside the interstate.
Check out this photographer's gallery, especially the Cadillac Ranch one:
Ben Willmore (http://thebestofben.com/)
Thanks guys for the encouragement. We decided to limp back to Queen City (near Texarkana) since it was within a day's drive. That way the bus will be here after vacation for me to live in while I work. We aren't giving up on the trip though. It's like you say, just altering the plan. My lovely spouse and I are sitting here in the bus planning what to do now. We are planning to head back toward Yellowstone, just trying to plan it out.
I thought about heading on to Amarillo and having the repairs done there tomorrow, but this way, we can put that off and have some fun. I will deal with the repairs later when we get back.
Just wanted to let you guys know that we were Ok,
Mike
Quotethe "not gen" light came on a few miles back.
Last year, after three solid days of driving, my Gen light came on in Texas. For a minute panic set in until I remembered reading a post that when the batteries reach full charge, on some bus systems (Old GM, MCI?) the regulator quits charging and the light comes on. I turned on the heater/AC fan to load the system and sure enough the light went out. I don't know if that is a GM thing or something that crosses manufactures, but I'm sure someone here knows. It only happened that one time after doing two nonstop 750 mile days. After the pace slowed down we were stopping/starting more often, and doing so kept a greater drain on the batteries.
Barn Owl is correct. Not sure how it would happen with your bus but with my MC9 if the solar panels are really kicking and I have the switch thrown connecting my house batteries to my bus batteries my Not Gen light will come on. I simply put my headlights on until I can throw the disconnect switch between the two battery banks and all is well in the world.
Mike
Quote from: Michael Mc on July 18, 2010, 06:29:51 PM
Thanks guys for the encouragement. We decided to limp back to Queen City (near Texarkana) since it was within a day's drive. That way the bus will be here after vacation for me to live in while I work. We aren't giving up on the trip though. It's like you say, just altering the plan. My lovely spouse and I are sitting here in the bus planning what to do now. We are planning to head back toward Yellowstone, just trying to plan it out.
First, limping home is the best thing that you can do.
Second, when you get there, replace the bad part. You have put good welds onto bad metal.
Third, rent a car and go have your vacation.
First, brazing an exhaust manifold is always dicy. There are some sophisticated and quite expensive rods that can stand up to the heat and vibration, but it's not good practice when other methods are available. That said, while some say you can clean previously brazed steel enough to weld, I personally cut it out and replace, or clean as best I can and re-braze with high temperature, high strength rod (I happen to use Allstate 11). Knowing that your manifold will almost certainly be a custom piece with the side turbo, my preference would be to try to find stainless steel to fabricate from and Tig weld it. That produces the strongest pieces.
Second, I notice that my Not Gen light does come on at idle when I have almost zero load on and the batteries are fully charged. Usually notice it at the end of a day of driving, I am hot, sweaty and tired, I am in traffic and my clutch leg hurts, therefore I am in a foul mood and it irritates the heck out of me! At least I no longer think my bus is about to fail!
Cheers, Brian