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Old 03-20-2016, 05:26 PM   #1
Bob-A
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Thumbs down Cast Iron + Stupdity = Failure

Just today I realized I had a crack in the Simmons intake manifold that
I had bolted on my '31 roadster. Long story short: I was trying to save metal on the intake. By spacing it away from the exhaust. Using a thin spacer between where the manifolds bolt together. Leveling the intake/exhaust port areas where they bolt to the engine block. See the latest issue of The Restorer page 55 on how I did this. And, it worked. However, I forgot to compensate for the thichnesses of the "ears" on the two separate manufactured manifolds! The differences in the ear thicknesses caused the crack when I torqued down on the clamping washer/nut. The reason why I was doing this. Was so if I ever wanted to change exhaust manifolds. It would be better to grind the $50 part (exhaust manifold) vs the $350 intake manifold. Leaving more metal on the intake for any future changes. I also have a Simmons on my '29 roadster and have had no problems with it. I did use a new repop exhaust manifold with it. When bolted toegther there was only a minimum of differences in the spacing of the ports up against the engine block. So I didn't even bother leveling them. The manifold gasket compensating for the minute differences.

I've got feelers out to my buddies hoping I can find a welder who can fix this very stupid problem I created. It has definitely ruined my day, week, month, etc.

Bob-A
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File Type: jpg Simmons broken ear 003.jpg (53.9 KB, 110 views)
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Old 03-21-2016, 12:04 AM   #2
Mike V. Florida
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Default Re: Cast Iron + Stupdity = Failure

The cupped manifold washers are supposed to compensate for that?

https://www.fordbarn.com/forum/showpo...0&postcount=26

and

https://www.fordbarn.com/forum/showpo...31&postcount=5
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Old 03-21-2016, 02:11 AM   #3
Bob-A
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Default Re: Cast Iron + Stupdity = Failure

Mike,

My original message was a short version of what caused the crack. I left out the part about that I also did not level the two manifolds together at first installation on the car. The differences in the space between the manifolds and engine block were insignificant or so I thought. The differences in this spacing combined with the intake/exhaust "ear" thickness differences. Probably worked together to cause the crack. At least that is what I am thinking.

Bob-A
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Old 03-21-2016, 02:18 AM   #4
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Default Re: Cast Iron + Stupdity = Failure

forever4, A PM has been sent.
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Old 03-21-2016, 07:53 AM   #5
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Default Re: Cast Iron + Stupdity = Failure

Bob-A, if misery loves company, I just got through putting a new $265 manifold on my 361 for a similar screw up. Its a sick feeling when you pop something and the revelation that you know what you did comes about a second later.
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Old 03-22-2016, 04:19 AM   #6
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Default Re: Cast Iron + Stupdity = Failure

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wbedwards,

My misery I wouldn't want company to have in any shape or form. I'm glad you were able to replace your screw up. I've got a line on replacing mine too. Good luck to both of us that we will not do it again!

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