Repairing / restoring FI parts

[Edward M.]

I just bought a plenum for a 65 Rochester FI. Just the plenum, no top, no manifold. It is in pretty nice shape, but has a number of the legs repaired (welded back on). It looks like someone did a nice job of it. I bought it because the price was right, and I was intrigued by it.

Anyone know who can restore something like this to show quality? It doesn't look like it has ever been polished or anything, just had the legs repaired.

I had this brilliant idea many years ago to adapt one of these 65 FI units to a 396 big block. Obviously, CFM limitations weren't being considered at the time.

What do I do with this thing?

[Dennis C.]

"What do I do with this thing?"...

On one or two visits to Brian Futo's home in AZ, I noticed he had put a couple of these to good use as outdoor planters... Very nice touch, I might add. I recall he was featuring cactus.

[John H.]

Re: "What do I do with this thing?"...

Might make a nice centerpiece if you have a coffee table like this

[Dennis C.]

John H., Now that is one...

...beautiful coffee table. DC

[Steve Pettit]

Re: "What do I do with this thing?"...

John, that is so very over the top cool. Do you mind if I download that picture. I want to give my daughter an idea for a Christmas present (smiley face).

Steve

[John H.]

Re: "What do I do with this thing?"...

Be my guest - BTW, that's a Buick/Rover 215 cu. in. aluminum V-8

[Steve Pettit]

Re: "What do I do with this thing?"...

Is that the same engine that was put in the 60's era little Buick and Olds cars?

[Christopher R.]

Re: "What do I do with this thing?"...

And Land and Range Rovers up until recently.

[Charles P.]

Re: "What do I do with this thing?"...

Notice also the wine bottles in the pistons. Very cool.

[G B.]

Welds will always show.

The '63-5 FI plenums were die-cast of an alloy that contained mostly aluminum but some zinc and other metals. Although lightweight like pure aluminum, this material is much more difficult to repair.

Its worst feature is its porosity. As a result, all used plenums are contaminated with hydrocarbons. These contaminants form bubbles in the weld when superheated. You can keep grinding out and welding over the holidays, but some bubbles will still appear at the junction of the new weld metal and the original plenum metal.

The second problem will be the color of the weld metal. You will not be able to match the sorta gray, marbled look with pure aluminum welding rod. The welded areas will always be a slightly different shade from the original casting.

The third strike will be warping from welding heat. It's certainly possible to surface the bottom of the four "feet" to make them true. However, almost every large flat surface on the plenum will be warped after several of the "ears" have been welded. The most difficult area to re-surface is the gasket face for mounting the air meter. Most machine shops don't want to even try.

I can't say I've seen every type of repair that's possible. I'm sure there will always be something new I've never tried. However, the bottom line for every welded plenum I've seen is that the repairs are detectable. If that's not okay with you, then I wouldn't bother to do anything with that plenum other than sell it to somebody who can love it for its good personality.

[mike mccagh]

Re: Welds will always show.

agree with jerry. once a doghouse has been welded its good for drivers and flower pots. bubbles always detectable after repair. just curious, is the plenum that started this post vin stamped or bare? mike

[Clem Z.]

to keep the "corvette theme" use a all aluminum

LS block.

[Clem Z.]

they did not show with the old orignal 1 piece FI

dog house we spilt down the center and welded back together so we could port them internally. NHRA and SCCA never caught on at least for a while.

[mike mccagh]

Re: they did not show with the old orignal 1 piece

you are refering to c-1 doghouses , aren't ya clem? regards, mike

[Edward M.]

Re: Welds will always show.

No VIN stamp on this plenum. Thanks to all for the info.