well, my dad and i worked on it for 3 hours. just about had the bolt out with the easy out when the drill bit broke inside the bolt. we tried drilling through it and then moving up to a bigger screw. even tried re-tapping the hole. nothing works. now it's butchered to the point where if i drill it out any further it will go through the water jacket. basically i'm screwed. im gonna have to buy a new intake manifold and then pay someone to put it on because i dont have the time or tools to do it myself. i was looking at the stage 2 manifolds on hughes engines, but i dont know if they'd accept mine as a core since it's sorta butchered. anybody have one? if not i could probably find one at a junkyard but i figure as long as i have to replace it, i mightas well get a better one.

 

drill the fer out or grind it off buy some ALUMALOY and fix it that way...

 

not sure how well that would hold up, besides, i'd still have to take off the manifold.

 

stronger than the man itself and yes you are correct

 

if i do all the work to take off the manifold, im gonna end up putting on a better one. besides, im not sure it would ever seal right and it would probably always leak a little. besides, i think it would be cool to have a built v-6. v8 swaps are pretty common, but no one really builds up a v6. a hughes engines stage 2 manifold and an f&b throttle body would probably be at least a 20 horsepower gain at the wheels, add on some harland sharp roller rockers and you can bump that number up to 35-40. another thing i just thought of would be since im gonna have to remove all the pulleys and everything to change the manifold, i might as well put on a double roller timing chain and tensioner.

 

better to swap a hemi in

 

bah cummins

 

can alumaloy be re-tapped? if it can, im going to take off the manifold, have someone fill the hole with alumaloy then retap it. And then, i'll send my manifold to hughes engines and have them port and polish it.

 

you can drill it out larger and helicoil it or have it tig welded up and redrill the original size

 

but wouldnt it cost alot of money to do that? i cant weld or anything. I came up with that idea because a guy I work with said that if i took it off, he said he would fix it with alumaloy. But the question is, would that stuff hold up to extreme heat and cold, and can it be retapped? I think if i drilled it out any further it would ruin the boss and it would never seal right.