Hello everyone. I'll be as brief as possible yet provide as much information as I can. The intake was installed and the motor fired-up - no smoke! Here's the short of it. I can describe to give anyone interested the long of it but only via private e-mail (so not to bore others....).
- The galley was not the issue. The angles between the heads with respect to the bulkheads were a perfect 35-degrees. There was no twist either. I purchased a Felpro angle gauge that is simple to use and works well to verify the angles. The head surfaces were block sanded to be sure the surfaces were relatively flat and the sanding prepared the metal surfaces quite well before assembly. Hardly any metal was removed because 120 grit belt sanding material was used.
- A word about the thickness of the metal around the ports.... The thickness on the face of the port surfaces should be no less that 0.125" for proper sealing. The interface between the intake and head requires at least this amount of metal.
- The manifold was certanly the issue. The port surfaces were not flat in the length-wise direction within the specified 0.002". I used a belt sander to knock off the high spots over the heat crossovers then a hand block sander to clean-up the surfaces. The angle gauge was used to measure the manifold to be sure it was true also. Always block sand and NEVER use an orbital or other sander of this nature. These sanders have a tendancy to round off the recessed areas (like around the ports!) and may cause sealing issues when the gaskets are installed. Block sanding both surfaces (head and manifold) is a way to be sure the planes are flat and parallel.
- The biggest issue was the bolt holes in the manifold. I found that the manifold was being held off the head surfaces causing incorrect sealing. The holes in the intake manifold were elongated to allow the manifold to drop into the galley creating proper seal on the gaskets. Indications are thread marks on the inside of the holes.
- I found that the cardboard material used for picture mattes works the best to test the imprint between the intake and heads. The thickness is only about 0.010" shy of gaskets and doesn't affect the fit. Two 3" x 24" pieces painted with flat or semi-gloss black paint with holes cut-out for the bolts provide an imprint showing surface pressure and alignment. It's cheaper than going through gaskets and can be had for free from most art supply or picture frame shops. Ask for scraps.
- The galley was not the issue. The angles between the heads with respect to the bulkheads were a perfect 35-degrees. There was no twist either. I purchased a Felpro angle gauge that is simple to use and works well to verify the angles. The head surfaces were block sanded to be sure the surfaces were relatively flat and the sanding prepared the metal surfaces quite well before assembly. Hardly any metal was removed because 120 grit belt sanding material was used.
- A word about the thickness of the metal around the ports.... The thickness on the face of the port surfaces should be no less that 0.125" for proper sealing. The interface between the intake and head requires at least this amount of metal.
- The manifold was certanly the issue. The port surfaces were not flat in the length-wise direction within the specified 0.002". I used a belt sander to knock off the high spots over the heat crossovers then a hand block sander to clean-up the surfaces. The angle gauge was used to measure the manifold to be sure it was true also. Always block sand and NEVER use an orbital or other sander of this nature. These sanders have a tendancy to round off the recessed areas (like around the ports!) and may cause sealing issues when the gaskets are installed. Block sanding both surfaces (head and manifold) is a way to be sure the planes are flat and parallel.
- The biggest issue was the bolt holes in the manifold. I found that the manifold was being held off the head surfaces causing incorrect sealing. The holes in the intake manifold were elongated to allow the manifold to drop into the galley creating proper seal on the gaskets. Indications are thread marks on the inside of the holes.
- I found that the cardboard material used for picture mattes works the best to test the imprint between the intake and heads. The thickness is only about 0.010" shy of gaskets and doesn't affect the fit. Two 3" x 24" pieces painted with flat or semi-gloss black paint with holes cut-out for the bolts provide an imprint showing surface pressure and alignment. It's cheaper than going through gaskets and can be had for free from most art supply or picture frame shops. Ask for scraps.
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