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Old 05-14-2010, 10:36 PM   #1
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Yeah, so many of you remember the trouble I went through with my bonneville when I first bought it.

Anyways, here I am, months later, just finished rebuilding the junk replacement motor I got, and lookey what happened today



Not fully put together, I need to replace the exhaust gaskets and donuts that I forgot to pick up, needs coolant too, didnt realize I was out. Just finished making a pipe for my intake, so that will be on tomorrow.

Anyways, I'm stoked. I have been half assing it an hour or so here and there for a couple months now, so I put in a full 11 hours of work assembling today and that is what you get.

BTW yes that is an aluminum intake manifold off a 91 lesabre.... I am not going to do a write up how to modify and install one, because it is more work than it is worth.

Last edited by FIND; 05-15-2010 at 02:08 AM. Reason: I just realized how weird my voice sounds on that video.
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Old 05-14-2010, 11:00 PM   #2
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Good work.
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Old 05-14-2010, 11:14 PM   #3
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nice! can u take some closer pics of the egr port so i can see how u did that
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Old 05-14-2010, 11:23 PM   #4
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Good job. It'* always nice when a project nears completion
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Old 05-14-2010, 11:31 PM   #5
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Quote:
Originally Posted by judgemikdredd View Post
nice! can u take some closer pics of the egr port so i can see how u did that
I drilled a hole in, tapped it to 3/8" pipe thread, added a nipple, cut the end off the original stove pipe, flared it and put a 5/8" flare fitting onto it. Sealed all the pipe thread with high temp thread sealant.

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The blue gasket sealant is temporary because I didn't have the correct TB gasket, and I want to drive it over to my dad'* house so I can weld the new rocker panels on this weekend.

For the vacuum port, I cut the mounting flange off for the old vacuum port and welded a new piece of aluminum in it'* place. Tapped that out 3/8" and added a tree. Tree is a nipple with some holes drilled into so I could braze some barbs onto it, then added an elbow up top for a barb for the brake booster.

Also note if anyone is intending to do this, you cannot reuse the plastic manifold'* bolts, they are too long aside from the one that is on the back right next to the TB which is too short. You will also have to shorten the tabs on the fuel rail because the mounting points are higher on the aluminum manifold. The old TB shield doesnt line up properly as you see, I will probably fix that later. The TB normally sits about 2-3 inches further to the drivers side, but the aluminum manifold is not as wide as the plastic one.

Like I said before..... It isn't worth bothering to do this. You can spend a few bucks more, get a brand new plastic manifold, and have no worries for longer than most people will own their car.
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Old 05-15-2010, 12:01 AM   #6
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Nice work
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Old 05-15-2010, 12:07 AM   #7
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With all the time I spent waiting for good weather to work in where I didn't have to spend all day keeping track of kids, I probably shoulda sanded down and polished that manifold.

FAIL.

Oh well, I am satisfied even without ricer shine.

Got a few electrical bugs to chase down behind the dash too..... Probably just loose plugs or something like that.
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Old 05-15-2010, 01:37 AM   #8
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Thats indepth
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