Please someone tell me this isnt going to cost a ton of money. I was tighting down the intake manifold to the intake plenum (sp?), and I heard a little bang and the bolt falls through pull other 3 bolts and the intake manifold and fin this




What are my options here

 

My guess is you can probably find a plenum cover pretty cheap from a wrecked truck. I am not sure the cost of them, but that is probably your best bet. The other option I see is maybe using J.B Weld, letting it harden, then drill and tap it. I would go with a replacement piece though.

 

It's not the cover. The piece that breaks off is cast into the head and the bolt go thru the intake cover and bolts into the little ear.

 

Maybe tap the hole? Just be sure to get all the shavings?

 

nothing there to tap. LOL

 

Oh ok, i thought maybe where the bolt gose down through?

 

believe theirs something called helicoil that mite help

 

What if you drill the hole out on the cover and tap the hole on the head. Then just find the right size bolt to fit that part. Maybe just build up the bottom of that hole with J.B. Weld and then re drill and tap it? Just throwing out some ideas...

 

yeh, the only problem is the hole in the aluminum cover is bigger than the bolt. Not to mention it would most likely create a boost leak. No sure if it could be welded up and fixed or not. I would be scared to use JB weld in this application

Also, the hole on the head is what already broke off.

 

Aw hell no, not helicoils!!!!!
Lloyd dosesnt like them there thingy's!

 

Everything has it's place! I just could have wore that stupid idiot out that thought it was a good idea to put them in 13 of the head bolt holes on the deck of a motor. LOL

 

OK, for those having trouble picturing the damage, this is what it looks like with the aluminum cover off the intake side of the head. In fact, this is almost exactly the way his looks, just a different spot that broke off.

 

Good excuse to get a ZZ intake plenum.I don't know what would be a good fix for that.I hate it for you man.

 

I have welded them with good luck. Had a customer come in that thought the air horn bolts needed to be as tight as head bolts and had broke two off.
We disassembled the top half of the intake, warmed the cast iron with a propane torch then used a mig gun to weld new ears on the head. After we just drill and tapped it. Not easy but a lot quicker and cheaper than a head. Tim

 

don't know what intake you're using but, the holes in my ATS are slightly larger than the bolts. I think if you were to thread the intake plate and find a larger bolt, it would work fine. The intake gasket would help prevent any boost leaks.