Intake crossover repair

Olds intake manifolds have huge crossover exhaust passages right next to a
cold fresh air/fuel passage. Other GM cars have crossover exhaust passages
but, they are much smaller than the olds. The olds has what is commonly
called a siamese center exhaust port with a huge passage through the center
of the cylinder head that connects to the intake manifold. I have several
NON TORONADO intake manifolds in my shop that are not dropped carb flange
intakes. They show cracks on the floor of the manifold just like the
toronado manifolds do. One of them I used for welding practice using
different methods and from that futile experiment (unsuccessful )
determined that they are generally NOT WELDABLE. So, block off plates are a
workable solution.
Other GM intake manifolds that are made of the same alloy of cast iron
(low nickel, low molybdenum, high carbon content) are also prone to
cracking. The high nickel content of the engine blocks themselves provides
some protection against cracks, in my experience. Just the way it is, I
guess.
Jim Hupy
Salem, Or
78 GMC ROYALE 403

> favor and stop reading the "hot rod Oldsmobile forum".
> 455 Oldsmobiles used in GMC"S have a huge load on them compared to a
> 4-4-2 or a Cutlass Supreme or a Toronado.
> The exhaust gasses from a GMC are much greater in volume as well as
> temperature, due to the 12,000 pound weight of the coach. The coolant and
> oil temperatures are much hotter as well. These extremes are what Crack
> manifolds.
> Jim Hupy
>
>
> I don't.
> I agree its a far higher load. However , I dont recall a problem with
> cracked intakes on SOBs with chevy 454s which have even heavier loads and
> far
> worse aerodynamics. Do they have a heavier cast manifold?
> I dont recall them looking much different than passenger or truck manifods
> other than the 'Peanut port' size.
> Exhuaust manifolds are another story entirely.
> --
> 76 Glenbrook
>
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
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>
 
​The SOB units run a much lower gear ratio of 4.56-4.78, so the load is not
so great as lugging the unit with a 3.07.
Also the Olds 455 and 403 has proportionately larger exhaust cross over
than the Chevy engines.​

> Olds intake manifolds have huge crossover exhaust passages right next to a
> cold fresh air/fuel passage. Other GM cars have crossover exhaust passages
> but, they are much smaller than the olds. The olds has what is commonly
> called a siamese center exhaust port with a huge passage through the center
> of the cylinder head that connects to the intake manifold. I have several
> NON TORONADO intake manifolds in my shop that are not dropped carb flange
> intakes. They show cracks on the floor of the manifold just like the
> toronado manifolds do. One of them I used for welding practice using
> different methods and from that futile experiment (unsuccessful )
> determined that they are generally NOT WELDABLE. So, block off plates are a
> workable solution.
> Other GM intake manifolds that are made of the same alloy of cast iron
> (low nickel, low molybdenum, high carbon content) are also prone to
> cracking. The high nickel content of the engine blocks themselves provides
> some protection against cracks, in my experience. Just the way it is, I
> guess.
> Jim Hupy
> Salem, Or
> 78 GMC ROYALE 403
>

>

> > favor and stop reading the "hot rod Oldsmobile forum".
> > 455 Oldsmobiles used in GMC"S have a huge load on them compared to a
> > 4-4-2 or a Cutlass Supreme or a Toronado.
> > The exhaust gasses from a GMC are much greater in volume as well as
> > temperature, due to the 12,000 pound weight of the coach. The coolant and
> > oil temperatures are much hotter as well. These extremes are what Crack
> > manifolds.
> > Jim Hupy
> >
> >
> > I don't.
> > I agree its a far higher load. However , I dont recall a problem with
> > cracked intakes on SOBs with chevy 454s which have even heavier loads and
> > far
> > worse aerodynamics. Do they have a heavier cast manifold?
> > I dont recall them looking much different than passenger or truck
> manifods
> > other than the 'Peanut port' size.
> > Exhuaust manifolds are another story entirely.
> > --
> > 76 Glenbrook
> >
> > _______________________________________________
> > GMCnet mailing list
> > Unsubscribe or Change List Options:
> > http://list.gmcnet.org/mailman/listinfo/gmclist_list.gmcnet.org
> >
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
> http://list.gmcnet.org/mailman/listinfo/gmclist_list.gmcnet.org
>

--
Jim Kanomata
Applied/GMC, Fremont,CA
jimk
http://www.appliedgmc.com
1-800-752-7502
 
> We sell lot of these Patterson Block of plate kits.
> We also supply the Electric choke which you'll need along with the plastic
> electrical connectors.
> --
> Jim Kanomata
> Applied/GMC, Fremont,CA
> jimk
> http://www.appliedgmc.com
> 1-800-752-7502
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
> http://list.gmcnet.org/mailman/listinfo/gmclist_list.gmcnet.org

Jim - It looks like I'm going to have to delay that order.
I'm going to have to go deeper than I anticipated. The engine has been running smoothly after initial startup. The rough running at startup I
attributed to running a little rich when cold. After a minute, it cleared up and ran so smooth it was hard to tell it was running at idle.

I decided to do a cold compression test before I took it apart. #1,3,5,7,2, and 4 cyls are at 150 psi - #6 at 140 psi and #8 at 60 psi. I had an
exhaust leak that turned out to be the exh gasket between #6 and #8 which I fixed. I'm going to do a leak down test tomorrow. There is no sign of
fluid loss, coolant in the oil or smoke so, I'm hoping it is exh valves.

--
Patti & Jerry Burt
73 Gmc 26' Canyon Lands -
Photos - http://jburt.smugmug.com/GMC-Motorhome
Lots of upgrades but lots to do to make it ours.
Members: FMCA - GMCMI - GMCWS - Pacific Cruisers - 49ers
 
My neighbor is a heavy equipment welder, taught me how to weld cast iron.
I used nickel welding rods, weld a little at a time, without too much heat.
And hammer on the weld to relieve stress as it cools.

I've been running this manifold for a few years.
Here's a link to the photo.

http://www.gmcmhphotos.com/photos/mechanical/p62724-manifold-repair.html
--
Bill Wevers GMC49ers, GMC Western States
1975 Glenbrook - Manny Powerdrive, OneTon
455 F Block, G heads
San Jose
 
Bill, I know that high nickel content welding rod, when used at low
amperage heats in short passes is effective on cast iron. And, if the
casting has minimal cracking, that will hold up for a long time.
But, if cobweb cracking is present like the Olds manifolds frequently
are, chances for success are slim. Blocking off the crossovers will help
prevent further cracks, but, if they go through the floor of the inlet
runners, you will still have vacuum leaks and oil consumption. But, if
yours is working well, good on ya, as Rob M. says.
Jim Hupy

> My neighbor is a heavy equipment welder, taught me how to weld cast iron.
> I used nickel welding rods, weld a little at a time, without too much
> heat.
> And hammer on the weld to relieve stress as it cools.
>
> I've been running this manifold for a few years.
> Here's a link to the photo.
>
> http://www.gmcmhphotos.com/photos/mechanical/p62724-manifold-repair.html
> --
> Bill Wevers GMC49ers, GMC Western States
> 1975 Glenbrook - Manny Powerdrive, OneTon
> 455 F Block, G heads
> San Jose
>
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
> http://list.gmcnet.org/mailman/listinfo/gmclist_list.gmcnet.org
>
 
If you have an urge to try this to repair your cracked cast iron manifold get some practice first. HIt the men's mall and pick up some iron manifolds
t practice on. The Way i was shown s to heat the iron hot, weld it and bury in hot sand. By hot I mean very hot, hotter the better. Or if I had to
do it I would find someone who knows how.

If you do practice, practice, practice and learn to do it, it is a great skill to have. Note the need for nickel welding rods.

No, I am not an expert but had one as a teacher. Haven't had the time or the need to do the practice.

Do note Paterson's advice that it is not needed if the crossover is blocked.

SteveS

> My neighbor is a heavy equipment welder, taught me how to weld cast iron.
> I used nickel welding rods, weld a little at a time, without too much heat.
> And hammer on the weld to relieve stress as it cools.
>
> I've been running this manifold for a few years.
> Here's a link to the photo.
>
> http://www.gmcmhphotos.com/photos/mechanical/p62724-manifold-repair.html

--
Steve Southworth
1974 Glacier TZE064V100150 (for workin on)
1975 Transmode TZE365V100394 (parts & spares)
Palmyra WI
 
Larry - Thanks. I've studied your photos before while doing my research.


> If you have access to a foundry, an option may be to pour and fill the crossover with aluminum. Look through these pics. Will give you an idea
> on how to handle this.
>
> http://www.gmcmhphotos.com/photos/g4571-pouring-the-455-crossover.html
>
> http://www.gmcmhphotos.com/photos/cad-500-intake-manifold/p12341.html
>
> JWID

Jim - I was leaning toward just using the Paterson intake gaskets but now you got me concerned about the spiderwebing. I have my extra manifold being
hot tanked now and will be tearing the engine down next week. Maybe I'll get lucky and the intake on the engine will be pristine. (Yeah, Riiight) The
intake and exhaust manifolds have been off before. So I'm hoping for some decent news after the heads come off.

It looks like Bill Wevers has his crossover filled also.

> Bill, I know that high nickel content welding rod, when used at low
> amperage heats in short passes is effective on cast iron. And, if the
> casting has minimal cracking, that will hold up for a long time.
> But, if cobweb cracking is present like the Olds manifolds frequently
> are, chances for success are slim. Blocking off the crossovers will help
> prevent further cracks, but, if they go through the floor of the inlet
> runners, you will still have vacuum leaks and oil consumption. But, if
> yours is working well, good on ya, as Rob M. says.
> Jim Hupy

--
Patti & Jerry Burt
73 Gmc 26' Canyon Lands -
Photos - http://jburt.smugmug.com/GMC-Motorhome
Lots of upgrades but lots to do to make it ours.
Members: FMCA - GMCMI - GMCWS - Pacific Cruisers - 49ers
 
Or, you could try doing it yourself. It worked well for me 10 years ago,
but I don't know if Mondello still sells the zinc. Some have reported
using old aluminum pistons -- I'm not sure my fish cooker would be hot
enough for that:

http://www.gmcmhphotos.com/photos/g3115-plugging-intake-manifold-exhaust-crossover.html

Ken H.

> If you have access to a foundry, an option may be to pour and fill the
> crossover with aluminum. Look through these pics. Will give you an idea on
> how to handle this.
>
> http://www.gmcmhphotos.com/photos/g4571-pouring-the-455-crossover.html
>
> http://www.gmcmhphotos.com/photos/cad-500-intake-manifold/p12341.html
>
> JWID
>
>
>
> --
> Larry
> 78 Royale w/500 Caddy
> Menomonie, WI.
>
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
> http://list.gmcnet.org/mailman/listinfo/gmclist_list.gmcnet.org
>
 
> My neighbor is a heavy equipment welder, taught me how to weld cast iron.
> I used nickel welding rods, weld a little at a time, without too much heat.
> And hammer on the weld to relieve stress as it cools.
>
> I've been running this manifold for a few years.
> Here's a link to the photo.
> http://www.gmcmhphotos.com/photos/mechanical/p62724-manifold-repair.html
40 years ago I knew a place that welded cast iron engine parts. They knew what they were doing. I saw a head that looked like a jigsaw puzzle that
they put back together, running a sawmill. If there were still places like that around, that would be the fix. But these days, nobody does that. The
stainless steel plates held in place by the gaskets are the best we can do.
--
73 23' Sequoia 4 Sale
73 23' CanyonLands Parts Unit 4 Sale
Upper Alabama
"When I grow up I am going to be a curmudgeon."
 
Ken H - Your series is another I looked at. Filling the crossover is still a possibility but welding is not going to happen. Cost vs an Applied GMC
replacement ($350) will be the major criteria.
--
Patti & Jerry Burt
73 Gmc 26' Canyon Lands -
Photos - http://jburt.smugmug.com/GMC-Motorhome
Lots of upgrades but lots to do to make it ours.
Members: FMCA - GMCMI - GMCWS - Pacific Cruisers - 49ers
 
I think I might have missed something but there must be plenty of old , perfectly good intake manifolds that were replaced by aluminum ones , that are looking for a good home. I have one that you can have for the cost of shipping. I have found JB weld fixes almost anything if applied properly. I built up the exhaust ports on my 403 after they were undercut by leaks and JB weld held up for over 50k miles and 11 years until I sold my Royale.

Jon Darcy ACES
North Jersey 76 stretch, flares, 4 bag, Alcoa's, bunkhouse,MAC Dash,Manny Trans, FiTech FI,Honda 6010
 
I would love it. If you can put it on a Greyhound to Fresno, CA. Let me know what it costs and will send you a check or PayPal it. you either take it
to the depot or they will pickup. I can pick it up from the Fresno Depot no problem. I can send you a check or PayPal is faster. Let me know. you can
call me: 5five nine . six 8 one one three 21

> I think I might have missed something but there must be plenty of old , perfectly good intake manifolds that were replaced by aluminum ones , that
> are looking for a good home. I have one that you can have for the cost of shipping. I have found JB weld fixes almost anything if applied properly.
> I built up the exhaust ports on my 403 after they were undercut by leaks and JB weld held up for over 50k miles and 11 years until I sold my Royale.
>
>
> Jon Darcy ACES
> North Jersey 76 stretch, flares, 4 bag, Alcoa's, bunkhouse,MAC Dash,Manny Trans, FiTech FI,Honda 6010
>
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
> http://list.gmcnet.org/mailman/listinfo/gmclist_list.gmcnet.org

--
Patti & Jerry Burt
73 Gmc 26' Canyon Lands -
Photos - http://jburt.smugmug.com/GMC-Motorhome
Lots of upgrades but lots to do to make it ours.
Members: FMCA - GMCMI - GMCWS - Pacific Cruisers - 49ers
 
Actually not as there is no reason to replace the OEM cast iron manifold
with the aluminum manifold unless it is cracked. The aluminum manifold is a
direct copy of the cast iron manifold.

Somewhere there is a photo sequence showing how it was designed.

Regards,
Rob M.
The Pedantic Mechanic
USAussie - Downunder
AUS '75 Avion - The Blue Streak TZE365V100428
USA '75 Avion - Double Trouble TZE365V100426
USA '77 Kingsley - TZE 267V100808

-----Original Message-----

I think I might have missed something but there must be plenty of old ,
perfectly good intake manifolds that were replaced by aluminum ones , that
are looking for a good home. I have one that you can have for the cost of
shipping. I have found JB weld fixes almost anything if applied properly. I
built up the exhaust ports on my 403 after they were undercut by leaks and
JB weld held up for over 50k miles and 11 years until I sold my Royale.

Jon
 
Or plug it with Hardblok which is what drag racers fill engine blocks with.

Regards,
Rob M.
The Pedantic Mechanic
USAussie - Downunder
AUS '75 Avion - The Blue Streak TZE365V100428
USA '75 Avion - Double Trouble TZE365V100426
USA '77 Kingsley - TZE 267V100808


-----Original Message-----
From: Gmclist [mailto:gmclist-bounces] On Behalf Of Ken
Henderson
Sent: Friday, April 14, 2017 1:06 PM
To: gmclist
Subject: Re: [GMCnet] Intake crossover repair

Or, you could try doing it yourself. It worked well for me 10 years ago,
but I don't know if Mondello still sells the zinc. Some have reported
using old aluminum pistons -- I'm not sure my fish cooker would be hot
enough for that:

http://www.gmcmhphotos.com/photos/g3115-plugging-intake-manifold-exhaust-cro
ssover.html

Ken H.

> If you have access to a foundry, an option may be to pour and fill the
> crossover with aluminum. Look through these pics. Will give you an idea
on
> how to handle this.
>
> http://www.gmcmhphotos.com/photos/g4571-pouring-the-455-crossover.html
>
> http://www.gmcmhphotos.com/photos/cad-500-intake-manifold/p12341.html
>
> JWID
>
>
>
> --
> Larry
> 78 Royale w/500 Caddy
> Menomonie, WI.
>
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
> http://list.gmcnet.org/mailman/listinfo/gmclist_list.gmcnet.org
>
_______________________________________________
GMCnet mailing list
Unsubscribe or Change List Options:
http://list.gmcnet.org/mailman/listinfo/gmclist_list.gmcnet.org
 
I have the intake manifold that Larry W. filled the crossovers with aluminum and am willing to sell it for $50 plus shipping. Contact me at
iagmc-at-yahoo dot com.
--
Gary Mau
X76 Royale
Davenport, IA
 
Jerry I changed the intake manifold after I installed the FiTech because of the terrible mismatch of the intake to the injection system. The Engine performed noticeably smoother with the Edlebrock than with the stock intake. As far as Greyhound is concerned there are no stations around here where it doesn't cost lots in tolls and unspeakable amounts in parking just to get to and drop it off. PA bus terminal is closest (25 miles). Parking in NY port Authority bus terminal is $45.00, Lincoln Tunnel is $15.00, NJ turnpike is $2.75, Garden State Parkway is $9.00 plus half day of my time getting in and out. I can try and send UPS , Fed X, or Post Office. When you get it you will have to clean it out as it has been sitting out all winter.

Jon Darcy ACES
North Jersey 76 stretch, flares, 4 bag, Alcoa's, bunkhouse,MAC Dash,Manny Trans, FiTech FI,Honda 6010
 
> Jerry I changed the intake manifold after I installed the FiTech because of the terrible mismatch of the intake to the injection system. The
> Engine performed noticeably smoother with the Edlebrock than with the stock intake. As far as Greyhound is concerned there are no stations around
> here where it doesn't cost lots in tolls and unspeakable amounts in parking just to get to and drop it off. PA bus terminal is closest (25 miles).
> Parking in NY port Authority bus terminal is $45.00, Lincoln Tunnel is $15.00, NJ turnpike is $2.75, Garden State Parkway is $9.00 plus half day of
> my time getting in and out. I can try and send UPS , Fed X, or Post Office. When you get it you will have to clean it out as it has been sitting out
> all winter.
>
>
> Jon Darcy ACES
> North Jersey 76 stretch, flares, 4 bag, Alcoa's, bunkhouse,MAC Dash,Manny Trans, FiTech FI,Honda 6010
>
> _______________________________________________
> GMCnet mailing list
> Unsubscribe or Change List Options:
> http://list.gmcnet.org/mailman/listinfo/gmclist_list.gmcnet.org

Ouch... Thanks for the offer but I think I'll pass. The weight of those intakes pretty much precludes shipping them UPS, FedEx, or USPS. Greyhound, if
convenient, would be bad enough. I think I'll just deal with the ones I have here. It will probably be cheaper in the long run.

Thanks again.

--
Patti & Jerry Burt
73 Gmc 26' Canyon Lands -
Photos - http://jburt.smugmug.com/GMC-Motorhome
Lots of upgrades but lots to do to make it ours.
Members: FMCA - GMCMI - GMCWS - Pacific Cruisers - 49ers
 
> I have the intake manifold that Larry W. filled the crossovers with aluminum and am willing to sell it for $50 plus shipping. Contact me at
> iagmc-at-yahoo dot com.

Gary - Thanks for the offer but I think I'll pass. The weight of those intakes pretty much precludes shipping them UPS, FedEx, or USPS. Greyhound, if
convenient, would be bad enough. I think I'll just deal with the ones I have here. It will probably be cheaper in the long run anyway.

I just did a power-wash on the engine today.
It is going to be interesting finding out what is in this thing. I still can't see the block number yet. Serial numbers show I have a '77 Cad Trans
and a '75 Non-Cal carb. The intake was painted competition orange then gloss black and the crossover didn't seem to be any hotter than rest of the
intake after I pulled it from the wash-rack to the stall. The block has no paint and the pan has peeling black paint.

I'll start the tear down tomorrow. No reason to work on a hot engine.
The treasure hunt begins. :)
--
Patti & Jerry Burt
73 Gmc 26' Canyon Lands -
Photos - http://jburt.smugmug.com/GMC-Motorhome
Lots of upgrades but lots to do to make it ours.
Members: FMCA - GMCMI - GMCWS - Pacific Cruisers - 49ers