Fixing gutted H22 plenum to retain EACV

[reklipz]

Hey folks!

A while back I purchased a gutted H22 plenum for a new intake setup. I didn't realize at the time that I would be unable to retain the EACV due to the massive air leak created by gutting the plenum.




As the title states, I would like to retain the EACV.

The best route would be to weld in some aluminum plate/filler to block off the openings, but I don't have access to a capable machine.

My next idea is to use JB weld to weld over the holes. I don't know how well using the epoxy type JB will work, as it is very runny I believe. Perhaps the JB stick type putty will work?

I'm cautious to use something like JB for fear of it breaking loose and getting sucked in through the intake. Can anyone comment on this; are my fears ill-founded?

What do you all think I should do here?

[toycar]

take it to a welder and stick to the original plan, presto!


I bet someone would charge you less than $50 to fix that.

['93CB7Ex]

buy a stock one and start over.

[reklipz]

take it to a welder and stick to the original plan, presto!


I bet someone would charge you less than $50 to fix that.

I'm looking around to see if there is anything I may have access to to weld aluminum. I know I have access to at least one 120 VAC MIG welder, but I don't know if that will cut it.

buy a stock one and start over.

It's tempting, but I don't think I would be able to recuperate the cost of this one, and money is tight. I'm going to try to repair it for me needs if I can. I can always postpone the project until I have funds or the proper equipment.

Really, I only need to plug two places: the small hole near the EACV, and the left side of the big opening in the photo. The plenum has a plug on the exterior for where that passage would normally feed. I'm not certain what would normally be there, if anything, anyway, so if it turns out that enclosing that passage is too difficult, then I will just fill it in.

[toycar]

Nah, for quality work the ONLY way to go with aluminum is TIG weld.


My opinion of course.

[reklipz]

Hmm... apparently it's possible to weld aluminum with a simple torch (propane or MAPP, depending upon the size of the material) and aluminum brazing rod. I know it's best to use a flux because of the lack of a shielding gas, but I may give this a try on a piece of scrap cast, or perhaps the hole that I don't care about. I've seen a few aluminum rods that describe themselves as not having a need for flux, "alumiweld" "brazing/soldering" rod essentially, apparently. Folks say it's best for filling voids etc. rather than a typical beaded weld.

I'm going to give this a try I think, and if that fails, I'll resort to getting it welded with some proper TIG equipment.

[Accrdwgnguy]

there is always that chance of the JB weld breaking loose. Your best bet is to have someone experienced with welding cast aluminum TIG those holes closed.

[oyajicool]

http://www.alumiweld.com/

Never tried this myself. But, interesting to know how well it does.

[Mishakol129]

Hey folks!

A while back I purchased a gutted H22 plenum for a new intake setup. I didn't realize at the time that I would be unable to retain the EACV due to the massive air leak created by gutting the plenum.




As the title states, I would like to retain the EACV.

The best route would be to weld in some aluminum plate/filler to block off the openings, but I don't have access to a capable machine.

My next idea is to use JB weld to weld over the holes. I don't know how well using the epoxy type JB will work, as it is very runny I believe. Perhaps the JB stick type putty will work?

I'm cautious to use something like JB for fear of it breaking loose and getting sucked in through the intake. Can anyone comment on this; are my fears ill-founded?

What do you all think I should do here?

That would really suck. I have the same concern. The break is not bad, from these pics can you tell if it will hold up?












Maybe what I'll do is when I put the metal spacer on i'll sandwich it with some more jb weld for extra security.

[SOHC-FTW]

No one can tell you if jb will hold, i mean come on now. What we can tell you is if it gets sucked down prepare for disaster.

[jdm92_accorn]

I wouldn't risk it. Does your car have a manifold on it that runs?

[Mishakol129]

I wouldn't risk it. Does your car have a manifold on it that runs?

It has the a1 manifold on it. Its just a big disappointment, I spent 165$ on this manifold with the TB. Think I can have it welded? Thing is its in such a tedious spot.


With the jb weld, heat is the main concern, I think this will work though. Its supposed to lower manifold heat. I'm going to get it and then use the jb welded manifold. I have faith it will hold up, I've heard of people using jb weld on intake manifold before and being just fine.

[Mishakol129]

No one can tell you if jb will hold, i mean come on now. What we can tell you is if it gets sucked down prepare for disaster.

Sure you can tell me, if you have ample experience with the product.