Intake Manifold corrosion replace or repair? OMC Ford 5.0

[cobraowner]

Putting motor back together and in cleaning up the intake I noticed a good bit of corrosion on the gasket surfaces at the back of the intake. (pics below) Most of them around the water port but some along the back bridge as well. I started looking for a replacment but have not found one that matches exactly. I found several on trucks in a salvage yard but they were missing the what I think is the deceleration valve pedastal at the rear of the manifold. It doesn't look like it has any other purpose other than to provide a landing spot for the decel valve.

I have also heard that replacing with aluminum aftermarket is a bad idea because it is raw water cooled and run in salt water. How bad an idea, will it just need to be replaced sooner than the cast iron manifod?

I have new heads and have had the block milled so those surfaces are good to go.
Questions/Options:
1. Can the intake be milled without messing up the clearances?
2. Just clean it up as good as possible and use a generous amt. of gasket sealer?
3. Aftermarket intake, rinse often, customize decel valve attachment?
4. Salvage yard auto intake customize decel valve attachment?



Thanks

 

[infideltarget]

Re: Intake Manifold corrosion replace or repair? OMC Ford 5.0

Aluminum will turn to powder fairly quickly in salt. This much I know. If the pitting is not too bad, I would think you could have it milled SLIGHTLY without messing up things too badly. I personally dont see why using a cast iron intake from a 289-302 car or truck would hurt, with the mild mods you spoke of, and I would think these would be fairly easy to find, as most of us with these engines usually toss them in favor of nice aluminum intakes.

EDIT: I just looked at your pics closer...junk it. Salt water is nothing to play around with when it comes to inside the sealed surfaces, and I think you would be playing with fire to reuse this one. It would make a nice and decorative anchor though!

Just my $.02

 

[cr2k]

Re: Intake Manifold corrosion replace or repair? OMC Ford 5.0

Doesn't look that bad from what I can see. Was it leaking prior to being taken apart? Maybe a little gasket sealing compound or aviation permatex would work good.

 

[cobraowner]

Re: Intake Manifold corrosion replace or repair? OMC Ford 5.0

Thanks for the input. I am going to take it by the machine shop tomorrow to see what they can tell me. If they have to take to much off to get the surfaces smooth that should give me an idea.

Any other suggestions versus an auto intake would be welcome.

 

[infideltarget]

Re: Intake Manifold corrosion replace or repair? OMC Ford 5.0

Thanks for the input. I am going to take it by the machine shop tomorrow to see what they can tell me. If they have to take to much off to get the surfaces smooth that should give me an idea.

Any other suggestions versus an auto intake would be welcome.

I think that is a solid plan, and a very good idea. The junkyard / auto intake is going to be the most cost effective way to remedy this. Maybe look into seeing if there is any way to seal the insides of an aluminum intake to prevent corrosion? Maybe a zinc dip (only the cooling water runners)? Maybe powder coating (again...only the cooling water runners)?