Mustang Sally Restoration: Fixing a cracked Explorer intake manifold and adjusting lifters

 So, we got the Stang running Wednesday night right as it was getting dark. After we drove the car around the block, when we got back from the short drive, I noticed the intake manifold corner bolt flange was cracked. Noooo!!!

Here's a close up view of the crack. We must have over tightened this bolt. Dad runs a thick phenolic spacer between the upper and lower manifolds.

Here's an inside view of the lower intake manifold port with the crack coming through. We were lucky this was not all the way through and didn't separate the pieces from each other. This made the repair pretty straight forward.

Brent knows DJ Whalen at Mt. Euro Werks in Tehachapi who has a BMW/European repair shop. He also builds turbo Bimmers and builds drift cars. 

Here's an outside view of the weld repair.

Here's an inside look at the repair job by DJ. As you can see, the weld bead needs to be ground down flat on the manifold mating surface and the inside of the intake port needs to be ground smooth as well for proper and even airflow.

Pops grinded smooth the weld repair and its looking good as new.

While running the engine, we noticed some lifter ticking noises. With the intake manifold at Mt Euro Werks getting fixed, dad removed some odds and ends and gained access to the roller rockers to adjust the lifters. 

Here he is going through the drivers side...

And on the passenger side. He adjusted every single one about a 1/4 turn...

Of course the intake mani came back on Saturday while I was on my way back to the airport to fly home. He got it back together Saturday afternoon and says its running really well now. Woohoo!!!