Lower Intake Thread Repair Solutions.

[dbrannon79]

Nice!

an old trick I was told about re-using gaskets (carb base gaskets) I would assume it would work on these too, is to coat them in vasoline so they don't stick. that way you can re-use them when your other intake comes back ready to install.

 

[jrsavoie]

Nice!

an old trick I was told about re-using gaskets (carb base gaskets) I would assume it would work on these too, is to coat them in vasoline so they don't stick. that way you can re-use them when your other intake comes back ready to install.

We always used grease

 

[MrMarty51]

Did that with the first intake. Did a lot of cutting on the upper half too trying to "improve" air flow inside. Still had to have the EGR on top since it is all open to atmosphere otherwise. Funny story (in hindsight) about that involving an SSDiesel 1st run 'Cold Air Intake Filter. I was fortunate to have found a set of intake gaskets that had the EGR ports blocked off. Haven't seen that type since.

Aluminum Spacer? Not a bad idea. I had hoped to have a chunk left over from the milling of my intake's spacer but, I gave all the scrap to the machinist who did the work. I'm going to leave the technique up to Chris.

Notifications tell me Amazon truck is just a few stops away. Time to get this Rube Goldberg repaired intake I've cobble together finished and the truck moved so I can get the pretty car in the garage before this new storm hits in a couple of hours.

This new pretty car statement.

 

[MrMarty51]

I have a lower intake with an upper intake bolt hole busted out.
I will, someday, get out the aluminum arc rod that I use, and the oxy/acetylene torch, knock off a fair amount of the flux from the rod and play with building that bolt flange back out then drilling and tapping new threads through it, just to see if I’ve got enough technique to make it work.

 

[Paveltolz]

This new pretty car statement.
View attachment 99024

Pictures of a butchered out upper and lower intake? Or do you want to see the pictures of the spacer and its morphing through development...from idea and concept, through wooden mock ups and a rough cut out by a local machinist, to a CNC'd piece that was once anodized, sorry, Purple?

The butchered unit didn't get pictures but, the spacer development was a 6 page thread. Some of the pictures are small but, you can zoom as desired. A lot of people from back then aren't here anymore. Just AKDiesel Driver I think is still active on the forums.

https://www.thetruckstop.us/forum/threads/intake-mod-other-project-or-two-and-finally-the-att.25488/

Hard to believe it's been almost 16 years ago.

 

[Big T]

Pictures of a butchered out upper and lower intake? Or do you want to see the pictures of the spacer and its morphing through development...from idea and concept, through wooden mock ups and a rough cut out by a local machinist, to a CNC'd piece that was once anodized, sorry, Purple?

The butchered unit didn't get pictures but, the spacer development was a 6 page thread. Some of the pictures are small but, you can zoom as desired. A lot of people from back then aren't here anymore. Just AKDiesel Driver I think is still active on the forums.

https://www.thetruckstop.us/forum/threads/intake-mod-other-project-or-two-and-finally-the-att.25488/

Hard to believe it's been almost 16 years ago.

Wait, I remember this (still scratching my head).

 

[ak diesel driver]

Your dating us Paul. My grey hairs show it too lol

 

[MrMarty51]

Pictures of a butchered out upper and lower intake? Or do you want to see the pictures of the spacer and its morphing through development...from idea and concept, through wooden mock ups and a rough cut out by a local machinist, to a CNC'd piece that was once anodized, sorry, Purple?

The butchered unit didn't get pictures but, the spacer development was a 6 page thread. Some of the pictures are small but, you can zoom as desired. A lot of people from back then aren't here anymore. Just AKDiesel Driver I think is still active on the forums.

https://www.thetruckstop.us/forum/threads/intake-mod-other-project-or-two-and-finally-the-att.25488/

Hard to believe it's been almost 16 years ago.

No, this portion of Your statement from that previous posting.


the truck moved so I can get the pretty car in the garage before this new storm hits in a couple of hours.

We would like to see what that pretty car looks like.

 

[Paveltolz]

The "Pretty Car" it is.
2024 VW Atlas Cross Sport. AKA, "Pain in the Atlas"

Pleasant to drive but, too many electrical gremlins. A subject worthy of another thread.

 

[MrMarty51]

A pretty car it is too.
Thank You for sharing, upon Your infirmation, seems a good one to put on the avoidance list.
One time, a V6 Audi in the pissant, oooops, passant. BILs car, cam shaft seal leaks.
That shore makes a horrible noise when them chain tensioners dont pump up quick enough, makes for poor horse power in the aftermath too.

 

[Paveltolz]

Small Update.
As I mentioned earlier, I am not at all thrilled with these stainless M8 x 1.25 threaded inserts (about $10 for six) but, they served the purpose of threading into the M10 x 1.5 Heli Coils I mistakenly used. I just don't think I could trust them to torque even to just the 17Flbs called for by the shop manual.


Likewise, I found the inserts from the Sennmon kit lacking in their feel of durability and would have prefered to use a carbon steel sert from either EZ-Lock or Timesert. Especially with the spare extrude honed lower intake I need a bolt hole 'foot' repaired or, a future replacement lower intake should I go that route. I pre-drilled and tapped this spare intake waiting for the longer serts to arrive which should be tomorrow.


As a refresher, The Sennmonn kit is a 'Time-Sert' knock off with the OD threaded at M10 x 1.25.

I decided against the EZ-Lock kits as they need the holes drilled out M12 for the 450-8 kit or 1/2"-13 for the 650-8 Kit.

I had mentioned that in hind sight I'd preferred to have used the carbon steel Time-Sert system but, pricy and I couldn't nail down the O.D. and thread pitch of their M8 serts. Well, I did some doom scrolling last night and discovered a user comment that listed the M8 inserts P/n 1812 as having M10 x 1.25 O.D. BINGO. Order just the serts and use the already purchased Sennmonn installation kit to do the job.


So, the cheaper feeling Sennmonn additional serts (14mm and 16mm long) will go back and cover the cost of the carbon steel Time-Serts arriving in two days.

Maybe I'll get a replacement intake for Father's Day? If so, I'll just drill it out and beef up the holes with these Serts from the git-go.