REPAIR HELP PLEASE!!!

My thoughts as well. If manifold is cracked just replace the #### thing. Doubt turbo flange is cracked. But maybe it is. Maybe they both just need to be surfaced, ground flat, could be warped

 

How does something get sucked into the engine on the exhaust side?

 

Well, when you have a crack in the exhaust manifold, it creates a loss of exhaust gas pressure which overheats the turbo and causes the EGT to rise. That significantly impacts the turbo fins and wheel as they overheat and expands them as they spin and cause the internals of the turbo to begin impacting the housing. At some point, the fins will begin to come apart and blow through the intake side.

I deleted a picture this week that would show the early results of this; this is where I would post it if I had kept it.

 

Have heard the term, but dont know much about it. From what I have heard it would probably be ok for something that doesnt have sudden and/or extreme temperature shifts.

 

You're wasting your time and money welding that. It's junk and belongs in the scrap pile. A good aftermarket manifold costs about $1,750+/- if you've been running since posting this where's your cash going? You could have bought and paid to have 2 or 3 of them put on by now. Even an OEM one if cheaper is not a bad option. Probably a better option for you.

 

Is your ISX a model with a variable geometry turbo? If so I would replace the manifold, the replacement turbos are ridiculously expensive.