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Repair: Aluminum intake manifold - broken bolt bosses

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  • #1

    Repair: Aluminum intake manifold - broken bolt bosses

    As some of you may recall, Clifton had a nasty crash earlier in 2010. This intake manifold was the one off of that car. The carb was knocked off of the car by the passenger side strut. It was found laying in the field some distance from the car. The following pictures show how it got like that, and what it took to make it look new again.

    FWIW - There's about 16 36" long welding rods in this particular repair.





    This is the intake stripped, and showing the broken bosses.


    Milled down and ready for welding....


    One corner welded...


    All four welded up, surface peened (helps increase density a LOT)


    Rough ground to shape...


    ready for milling....



    Complete!
    Tags: None
  • #2
    Wow!

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    • #3
      Repair vs replace cost? Good work Brooks.

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      • #4
        Nice work, but aren't those intakes pretty cheap?

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        • #5
          How do you like that mill? Brand?
          Originally posted by Taya Kyle, American Gun
          There comes a time when honest debate, serious diplomatic efforts, and logical arguments have been exhausted and only men and women willing to take up arms against evil will suffice to save the freedom of a nation or continent.

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          • #6
            Intake plus port work plus milling to fit the heads/motor.
            Cheaper to fix it for sure.

            Thanks Brooks! Looks good.
            Last edited by Clifton; 02-24-2011, 08:05 PM.

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            • #7
              As Clifton said above, it's custom fitted to the engine and has some nice port work on it - WAY cheaper to fix it...but yeah, if it were a box stocker, I'd just replace it instead.


              Darren, the mill is Chinese made and imported through a vendor in Canada called www.machinetoolswarehouse.com. It's the biggest mill you can get for a "benchtop" type machine with a 32"X, 12"Y, and 16"Z travels. It works great and is rigid as hell. It's also the only one I could find that uses NMTB30 tools instead of R8.

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              • #8
                Nice. I had to get rid of my 3 in 1 a couple of years ago and miss the ease of making my own stuff. Thanks for the link!
                Originally posted by Taya Kyle, American Gun
                There comes a time when honest debate, serious diplomatic efforts, and logical arguments have been exhausted and only men and women willing to take up arms against evil will suffice to save the freedom of a nation or continent.

                Comment

                • #9
                  This type of work makes me horny!

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                  • #10
                    Great job, like always!

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                    • #11
                      Originally posted by jason07 View Post
                      This type of work makes me horny!
                      WOW... Brooks makes everyone horny
                      Badass work!

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                      • #12
                        Originally posted by FRANCISCO308 View Post
                        WOW... Brooks makes everyone horny
                        Badass work!
                        Nevermind him Francisco, he's just gay and proud of it.

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                        • #13
                          Originally posted by turbostang View Post
                          Nevermind him Francisco, he's just gay and proud of it.
                          I don't think gay is a strong enough word to describe him.

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                          • #14
                            Time for some fresh powdercoating!

                            Looks good man.
                            One day at a time.

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                            • #15
                              Outstanding work Brooks.....

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