Intake Manifold is FUBAR!!!

[COBALT]

I went to replace my thermostat, which has started to fail on me and hasn't been replaced in 1000 years, and promptly broke the shorter mounting bolt, so I spent the day trying to drill the bolt out and get a clean hole for some new threads.

Just when I got to where I have some decent threads (had to go to 1/2 tapped!) the tall side broke. Now I have to drill that one out too. God, I'm really tempted to use this as an excuse to get a new intake, but I"m afraid the intake bolts will be in the same shape. Anyone else go through this? Did you just retap holes? What size? I'm feeling a bit wierd having 1/2" where 3/8" used to be...

[Big69C20 Toy]

I'd say you should get a new intake, they arent too much, in fact i saw at least one on the parts board. Give those bolts all a good drenching like 3 times in penetrating oil and you shouldnt have such bad luck taking them out i dont think. Regarding the changing of bolt size i'm not so sure but in certain areas it's much more critical than others, up at the thermostat i think you're pretty safe.
Good luck man

[mikep]

check with some industrial supply places like mcmaster carr or grainger J&L industrial or whatever you have in your area. I often use a thread replacement unit that is essentially a 1/2-13 threaded plug with 3/8 coarse internal threads. Jergens makes a good one that is held in place by small pins. There is another one that epoxies in place as well.You could roll your own with a lathe if you had a friend with a lathe. You're too far gone for helicoils but helicoils wouldnt work well in that application anyway.

[Desert Rat]

Maybe time for a Performer?If intrested i can pick up a intake for you,but shipping that lovely cast aint cheap,id only charge whatever my buddy charged me-probably be free or $5 at most.but shipping would be well over $20 email me to let me know if you need help,and what year etc.

[misfits]

make sure you put anti seize on the bolts before you put them back in.

[COBALT]

For anyone who cares I managed to get the thermostat housing off without busting the tall side like I did the short side. I managed to drill it out enough to tap the housing off, then I turned the broken stud out with a cold chizel.

Now all I have to do is see if the short side is salvagable. If it isn't I'll be getting a new intake, so cross your fingers...

[68SWB4x4]

i wouldnt even bother messing with it, cast iron intakes are EVERYWHERE i can get as many as i want for free..... but i have about half a dozen of my own im trying to get rid of
if i were you id get a edelbrock intake though, i love the one i put on my 70

[COBALT]

I'd be all over a new 4bbl intake if I had the $$$. I don't want to go to the trouble of putting a used intake on if the one I have alreay on there is salvagable. Basically my choices right now are salvaging the one I have or getting a used one.

In a couple of months I might be able to shift to 4bbl, but not now.

[Fast68Chevy]

just get another one, theyre too common to be messing with your busted one... the bolts that hold it to the heads wont be froze like that, they are near oil all the time. they will be ok.

good luck

[PitterPats72]

Get this stuff called aerokroil. It's from a company called Kano Labs in Tn. There web site is www.Kanolabs.

This stuff was designed for the aircraft industry. They have some great other stuff too. Degreaser and all kinds of other stuff. Aerokroil seeps down into the tienest spots, it's awesome.

I just got a used intake manifold from a junkyard and the thermostat and carb bolts were rusted in. I sprayed this stuff on them and in about half hour they were free. Last year I had to tak one of the exhaust manifolds off and the same thing except it was worse. After about 3 days of spraying when I thought about it and tapping it a couple of timea a day they were free,

So think about this stuff, it's great.

Pat