Well let me first start by saying !@%$@%#!

Also, let me say that I know I am an idiot for attempting a plenum mod at night with little light.

With all that said I made a slight mistake with my plenum mod. See the lower middle attachment point and the material missing. (Warning - high resolution picture if you click on it - not for the dial up user) :)

Will this still work? It seems it would as long as the bolt is tightened down good since it would have a new gasket.

Thoughts?

http://www.msu.edu/~lemansk5/mistake.jpg

MSU

Where is the pic?

Weird, I inserted it into the message and I can see it when I look at the post.

It is linked here in the full size

http://www.msu.edu/~lemansk5/mistake.jpg

Sorry.

My understanding is that you can remove all the material except the EGR seat. It looks like you've left the EGR seat but you've ground it down some so the seal won't be good....is that what I'm observing here or not?

MSU, if I see what I htink you are talking about in the under cut and missing material on the two center bolts, IMO this is a pressure system not a vacumn sytem, so if you used permatex or silicone in the under cut and missing material area it should produce a seal that would hold boost pressure not allowing the sealant to escape between the gasket and the plenum. If it were a gasser it would present a problem in that the sealant would be sucked into the intake. The boost pressure is trying to force the sealant out so you should be OK. Good luck.

youll be fine just use a little extra atv silicone there:D , these intakes arent tightened down that tight and arent under that much pressure so youll be fine

To err on the side of caution, I'd just snip off the edge of the gasket that won't be compressed between the two halves so it's not flopping around in there and just keep on keepin' on.
http://i30.photobucket.com/albums/c348/kaaooga3/diesel%20place/intake.jpg (http://i30.photobucket.com/albums/c348/kaaooga3/diesel%20place/intake.jpg)

the outer edge and the EGR circle are the sealing points. make sure they are flat and level.

glenlloyd stated above that it looks like there was material taken off of the center EGR tower. If that's the case it won't seal. If the lower EGR tower was blocked off I guess it wouldn't matter.

Okay Guys,

Sorry about not replying - it was going on 1:00am here and I had to get some sleep.

I don't see the EGR tower being an issue and in fact was thinking of just taking it right out.

Ha - got some of ya - :)

Here is a picture of my intake - since I don't have an EGR it seems pointless to have it there other than maybe structure just to keep the top of the plenum from caving in if it were hit with a hammer or something.

http://www.msu.edu/~lemansk5/intake.jpg

http://www.msu.edu/~lemansk5/intake.jpg

The area I was refering to was indeed where "jackb" pointed out. I will cut away some of the gasket.

The only major concern I have at this point if you guys reference using silicone. There wasn't any in there when I took off the plenum or intake so I didn't put any back on.

Should I have used silicone on the intake?

Will the intake and plenum be fine with just the gaskets?

I really don't want to have to rip that entire intake assembly off again if I don't have to. That was a pain in arse.

Thanks guys!

MSU

Wow you really gave that puppy a close shave. Reference for those trying this in the future.....you don't have to trim it so close!

There is more pressure here then you think and you'll know in a hurry if you have a leak. It will be a high pitched whistling sound and you'll be able to see on the engine where the leak is. There will be oily residue everywhere.

I would use the RTV even though there wasn't any there before. Lots of guys do. It just helps seal up any imperfections that the gasket can't. Make sure you don't try and get a better seal by over torquing the bolts. The metal on those intakes is pretty soft and you can easily damage it. I believe the torque specs is only 17 ft/lb.

The EGR tower is not an issue since you don't have an EGR lower. It looks like you had one of those F upper intakes that had the webbing like a S upper but doesn't have the opening for the EGR valve.

Let us know how you make out.

Dave

RTV (red) will take care of the imperfections from overzealous grinding, then if you wish you could try to find a junkyard a real F upper that is flat top with no EGR casting for restoring to a no RTV required sealing surface

Thanks guys!

Is at a necessity to rip the intake back off and silicone it? It was such a pain to get back on and keep those little plates in the gaskets. I really don't want to have to rip it apart again if I don't have to.

TD,
You mentioned red silicone - I have some of the black stuff that says it's for gaskets - is it that big of a difference?

Thanks agin guys - you're life savers (literally - my wife said shes going to kill me for putting so much time / money into this thing.) :)

MSU

Not that big of a deal Red is Hi temp and I just prefer the red, it is good stuff I've been using it a lot of years, and you would be surprised to know how many jet parts come red RTV'd new per factory drawing spec.

Thanks TD!

Last question (for now until I screw something else up - LOL)

What is the consensus about pulling the intake back off for a little silicone?

MSU

I myself would go drive it first and see if it leaks. If no leaks (obvious/obnoxious howling or screaming noise) then you are probably good to go. I had one gasket leak because a tiny amount of the old gasket had not been scapped off. Make sure the mating surfaces are squeaky clean and it should be alright.

If it ain't broke, don't fix it.

Yep...I had the same thing Silvy. You'll know if it's leaking. Try it first the then pull it if you have to.

Dave

Okay Guys!

Thanks!

We are leaving for the weekend so I will have to do it Monday after work.

I'll let you guys know how it goes.

Thanks again for all the help!

MSU