Ok, based on the number of e-mails and pm's i've gotten on this topic in the last 8 hours, I can see there is a lot of interest in this topic. So, i've decided to create this thread to cover everything that gets done on my intake from start to finish, good or bad. Feel free to join in the discussion, but lets try to keep it on topic for this thread so it is a valuable and easy write-up for others to refer back to in the future.

Steve, if you don't mind, i'll rely on you to insert the techical tidbits as I go - guidance so to speak. You say what to do based on your experience, and i'll do it (or a variation based on my research) and post pics as I go along.

Ok, here goes.

 

Here is the spare intake I am starting with. It looks like it came off an older truck (probably '97 or older) as it still has the egr ports, and the huge center divider that Chrysler did away with in the later years. To start with, I had it cleaned up in a dip tank at my local machine shop, and had them check all the surfaces for true-ness (to make sure it wasn't warped or anything, and would make a good seal when I go to install it). They offered to media blast it too so it would look all shiney, but that seemed like overkill to me (even though that would have looked bad ***).

So here are the first "before" pics:


[IMG]local://upfiles/9095/4A34B9DFF7C74A52A44465AEE5F7F1CF.jpg[/IMG]

[IMG]local://upfiles/9095/32FF7B0560B94D9091B4EA0869A76BE4.jpg[/IMG]

[IMG]local://upfiles/9095/DE603FCC70BB48B78E4C15117C2FB788.jpg[/IMG]

[IMG]local://upfiles/9095/6EA04572F6B44DA3871414190A1C97C0.jpg[/IMG]

[IMG]local://upfiles/9095/FCF762AA13AB455EB1A1159F439E9E78.jpg[/IMG]

 

what was the price on the machine shop service?

 

For the cleaning and the machining, it was $25 I think, something like that (didn't actually need any machining though, it was perfect). He wanted another $20 or $30 I recall for the media blast.

 

thats one thing i regret doing when i did my pan fix, should modded the kegger while it was off...

thinking of going the M1 route anyway. (with cam/heads, higher compression)

but thast for a different thread

are you gonna paint the kegger anything or leave it bare?

 

I think leave it bare.

 

Purchased the repair kit today. I ordered the deluxe kit from APS Precision. Solid billet aluminum plate, 1/4" thick, plus gasket kit and new intake bolts.

http://www.apsprecision.com/billetplenum.html

[IMG]local://upfiles/9095/34574B93D2D244F5AC80C8A08C28B7B6.jpg[/IMG]

 

when are you planning on doing the cutting? I posted in the other thread that I'm heading over to home depot shortly and will get the p/n's of the bits I used. I used a rotozip with a beefier mandrel for the cuttoff wheels as I was snapping the mounting screw far too often. I got that mandrel @ sears. If you compare the dremel mandrel to the one I used it's about 50% bigger. While others will tell you to use a sawsall or larger cuttoff wheel (disk grinder type), I found I could not get either in a position to make the cuts I wanted so I went to the rotozip. (dremel does not have enough torque... broke mine on the 1st runner).

 

Here is a link to mine https://dodgeforum.com/m_552473/tm.htm
My machinist wanted to take out the center divider. Had I the time, I would have. I only knocked mine down 1" or so.

 

I was planning to start cutting soon, maybe this weekend. I was going to try using my Dremel. I don't plan to buy any new tools for this project (have to save a little $$$ on this one), so I might have to get by with the Dremel and just taking my time. Or I might go the sawzall approach that others have done, and then clean it up with the Dremel. Based on your comments though, I might try to borrow a better rotozip if I can find someone that has a good one.