Very nice man! Ill have to try to weld some alm. Now i never done it im scared to make this my first project :/

 

Welding aluminium takes some serious skill. Ive just started learning to TIG, definitely an advanced form of welding.

 

There's a ton of good info out there to help you out. Miller has an "aluminations" article I came across online one day, goes into great detail about setting the machine properly for what material you are using. I've found that is the major thing on aluminum, the machine has to be set right. If you get the welder dialed in, and have a steady hand, the rest of it is easy. Nothing like welding steel, where you can kinda work with what you have and it's still good. Poor aluminum welding is a nightmare.

Also, beware of too much heat into the endplate. Castings like that tend to warp or crack with excessive heat. One reason why I don't like welding them for dual-pass applications.

 

how do those cores come out? havn't really looked at it much but i've tried to just pull them out but no luck yet..

 

Nice write up

 

Safest bet is to grab them with some rubber-jaw'd pliers. They are very soft alumnium, and if you squeeze them hard at all they will dent in. Grab them as light as you can and turn them, once they turn a little they should pull right out, there's just an o-ring on the inside same as what's in the endplate.

 

alright kool so turn then pull..

 

I was thinkin about making one of these but i have no welding tools or experience so i was wondering if you could do this without welding. Could i just drill a hole into one, tap some threads into it and then wrap the new piece im putting in in teflon tape?

 

If you do it carefully, yeah. If you're trying to do it with a hand drill, good luck to you. The minimum size you have to drill for is 1/2"NPT which is a 23/32nds drill I think. If you are gonna do that, use some pipe sealant, Rector seal or similar, rather than teflon tape.

 

Does anyone have the torque specs for the bolts on the intake manifold?

 

i remember reading that you need to torque them down to 98lbs or so

 

From intake manifold to head is about 18lbs I believe, nothing serious. Good and tight by hand with a 1/4" ratchet will be plenty. The lower support bolt can be pretty tight, but don't get carried away on the flange bolts.

 

did you have to drain any coolant before doing this

 

the coolant out of the intercooler system, yes, engine coolant, no..

 

Hey just asking LOL best place to drain this

 

pull one of the hoses off of the intercooler pump haha

 

How do you exactly take off the intake manifold? I remove all 5 bolts and 2 lugs but it doesn't come out. I tried to pry it out but its to uncomfortable to put a screwdriver between the block and the manifold.

 

Nice

 

I just realized that previous owner did a dual pass on my car. He drilled tapped into the manifold and whatever he used to hold the connector in place wore out and i can pull it completely out. Is there a way I could put something back on it to hold it place for at least an immediate fix? School is almost over but until then i dont really have time to take off the endplate and properly weld or whatever. So what do you guys suggest? Heres a pic to get an idea of what he did....

 

Woops sorry for such a big picture. But you can kinda see how its coming off a lil bit.

 

lol that dual pass looks like crap

 

i know :/ should have seen the exhaust he did... sheesh

 

weld it
and check the cores are flipped correctly

 

[QUOTE=juice3;5734801]I just realized that previous owner did a dual pass on my car. He drilled tapped into the manifold and whatever he used to hold the connector in place wore out and i can pull it completely out. Is there a way I could put something back on it to hold it place for at least an immediate fix? School is almost over but until then i dont really have time to take off the endplate and properly weld or whatever. So what do you guys suggest? Heres a pic to get an idea of what he did....

Looks like you have a JB weld dual pass

 

Yeah i def plan on doin that when i have time this summer but is there a seal or something i can put on it for now to hold it on?