[Got-Torque]

Just got the car back together and running after all the deletes, JR 2.8 tune, airbox mods, provent install, intercooler, etc. Took it for a quick spin and man does she run now! Haven't gone full throttle yet because I'd like to quicken up the shifts in the trans first.

Anyhow, after looking things over after the drive, I noticed some fresh oil splattered around the egr delete mount to the intake manifold. After cleaning it up and inspecting with a mirror and light, it appears it has some cracks in it. Almost like someone put too much pressure downward on the egr mount and cracked the manifold along the top edge...

This would explain all the crud/oil buildup under the manifold I found when I took it apart. I thought maybe the gasket was leaking. It all has new gaskets now though.

Anyone have an intake for sale?

On another note, what kind of boost number should I see with this tune? I think my torque app showed a max of 40?

[Yozh]

Strange it would be cracked, as brass pen-nuts should prevent damage like that. Depending on how deep the cracks, the gasket should prevent the leaks as well. Would be curious to see the photo.

[Got-Torque]

The crack starts behind the half inch thick rectangular mount for the ego delete, and wraps under the first intake runner towards the passenger side. Probably 2" long. I didn't get a pic and already cleaned it up and used some right stuff rtv to try to seal it up. I have had great luck with this stuff in the past and hope it holds until I can find a replacement manifold.

[335stoner]

the rtv will not hold if is see's any positive pressure... you would be better drilling cutting and filling the crack if you want it to hold and not spread.

[Got-Torque]

Originally Posted by 335stoner

the rtv will not hold if is see's any positive pressure... you would be better drilling cutting and filling the crack if you want it to hold and not spread.

it's just a hairline crack, and the "right stuff" is pretty darn good... I'll check it tonight and see how it did today. Obviously though, I would like to get it replaced. I wish the intake was aluminum and I could just tig it...

Anyone ever made a replacement intake manifold for one of these out of aluminum?

Realoem shows the manifold over $600 I think...

[Got-Torque]

RTV didn't stop it from leaking, went ahead and ordered another manifold from husker. Just over $1000 for a darn plastic intake manifold... ouch

[9mmkungfu]

Originally Posted by Got-Torque

RTV didn't stop it from leaking, went ahead and ordered another manifold from husker. Just over $1000 for a darn plastic intake manifold... ouch

Could you cannibalize this one?

http://www.ebay.de/itm/252796785197

[Torqu3]

Originally Posted by Got-Torque

RTV didn't stop it from leaking, went ahead and ordered another manifold from husker. Just over $1000 for a darn plastic intake manifold... ouch

Is it seriously plastic? As hot as our engines get, I can't believe plastic holds up. Maybe someone can 3D print one.

[Got-Torque]

Originally Posted by 9mmkungfu

Could you cannibalize this one?

http://www.ebay.de/itm/252796785197

Looks like it would have worked... Don't know what shipping would be to the US or if it would make it undamaged...

I've ordered smaller parts from overseas and made it ok, I just start to worry when it's bigger items that could get damaged and your buying from a private party. Then you are at the mercy of the insurance of the shipper and it often takes weeks to get a decision made as to who was at fault...

I wonder at what boost limit will the plastic intake explode on one of these cars? I blew the side out of a custom water to air intercooler on my dodge ram at about 55 psi (1/4" aluminum plate). We had to add straps to strengthen it up...

[9mmkungfu]

Yeah, and it could take some time to get here.

It looks like there are a couple of used ones on car-part.com if you're interested in trying that route:

$450 here http://www.arofkansas.com/
$500 here http://www.basicautoparts.net/

[Got-Torque]

thanks!

[BB_cuda]

Got-Torque, check for a PM from me. You will not be sorry

[BB_cuda]

Another PM for you. Checking portion of address👍 Package is ready to ship!

[BB_cuda]

Originally Posted by 9mmkungfu

Could you cannibalize this one?

http://www.ebay.de/itm/252796785197

This manifold looks same as one I'm sending. EGR is different.

[Got-Torque]

Major thanks to BB_Cuda for helping me out on this!

[BB_cuda]

Originally Posted by Got-Torque

Major thanks to BB_Cuda for helping me out on this!

You're quite welcome. One more PM with tracking number and other info.

[Yozh]

Cuda, you deserve a lot of rep points.

[DozerDan82]

I see you have this sorted, but any pictures of the crack. I have had great success with the soldering iron with plastic repair, it takes some technique but once you get the feel for it (which you will if you can tig) it is very effective.

[Got-Torque]

I'll take some pics when I swap it out...

[BB_cuda]

Did everything come back together okay? I know you were waiting to test drive due to bad weather.

[Got-Torque]

Yes went back together great, just didn't finish up my meth nozzles or wiring yet and had to drive it to work. I'm trying to determine what is normal or typical for boost/drive with a stage 2.8 tune I guess. Leaning on it on the way in to work a couple times this morning, but no full throttle and my drive is approx. 10-15 psi more than boost.

I need to figure out how to log on the Torque app so I can get some good data. Just watching the gauges I think I saw about 35 boost 48 drive however at some point lower in the rpms the drive spiked to about 51.

[TDIwyse]

Originally Posted by Got-Torque

Yes went back together great, just didn't finish up my meth nozzles or wiring yet and had to drive it to work. I'm trying to determine what is normal or typical for boost/drive with a stage 2.8 tune I guess. Leaning on it on the way in to work a couple times this morning, but no full throttle and my drive is approx. 10-15 psi more than boost.

I need to figure out how to log on the Torque app so I can get some good data. Just watching the gauges I think I saw about 35 boost 48 drive however at some point lower in the rpms the drive spiked to about 51.

Boost, and especially EMP, change dramatically through the rpm range (the HP and LP turbo hand-off radically changes the EMP behavior in the mid rpm region).

I've found logging data vs rpm is critical for knowing how the system is behaving. TestO is a better tool, but Torque with DWR's custom PIDs is still pretty good if your pulls last long enough for Torque's lower sampling rate to get a decent number of points across the rpm range. 3rd gear up a steep hill while sampling ~4-5 things in Torque is barely OK. 4th gear pulls are better as they last longer (more data points), but your speeds get dangerous.