How can i fill it up?
Its really small... Maybe 1mm*2mm.
Can someone tell me how to patch it up?
While i wait for an answer let me keep sanding the other ports smooth... mad.gif


https://i293.photobucket.com/albums/...3/DSC01027.jpg

https://i293.photobucket.com/albums/...3/DSC01025.jpg

A very small hole has a small surface area to pull in through, so a daub of high strength/high heat epoxy should do nicely.

If you've ported the wall that thin, you've gone too far. Time to start over with a new one.

I saw intake, so I thought intake, this was your intake MANIFOLD bored that thin?

Guys, if it's just a hole, as stated, it's no problem. If it's ground very thin, still no problem. It just takes more epoxy over more area. If you can push on the aluminum with your finger and deform it, it's too thin. Spread a thick coat of strong epoxy over the thin aluminum and you'll be fine. Larry Widmer from Endyn said that when they removed 2lbs of aluminum from an intake during a porting job, they spread epoxy over some spots to keep it from collapsing under vacuum.

The air doesn't know what keeps it from collapsing the intake wink1.gif Also remember that some of the newer cars have plastic intake manifolds.

I do agree that epoxy on that one spot would prevent the hole from being an issue.

However, like cobra said, if you've ground the entire intake down that far, you're setting yourself up for problems with warping/bending, whether that be from the weight placed on the intake itself, heat stress, the manifold possibly hitting the firewall, etc.

<div class='quotetop'>QUOTE </div><div class='quotemain'>i8acobra Posted Yesterday, 05:27 PM
If you've ported the wall that thin, you've gone too far. Time to start over with a new one.</div>

Stop being so negetive.
Im not mechanically inclined but know how thin to go...
And im not that of a pro to make all the runners that thin.

I can press that hole down hard and it wont move...
So its not too thin.
And no i dont need to start a new one...
Dang... It was such hard work to do this...
Ill take pics once patched up.

Thanks for the advice guys.
I actually want to get it welded by engineering and then regrind that part.
Im scared epoxy might wear out over time.
I never used it before.

Epoxy won't wear over time, it's just air moving around it.. just make sure you spread some on both sides of the hole

<div class='quotetop'>QUOTE (daneeboy83 @ Jun 11 2009, 01:00 AM) <{POST_SNAPBACK}></div><div class='quotemain'>Stop being so negetive.
Im not mechanically inclined but know how thin to go...
And im not that of a pro to make all the runners that thin.

I can press that hole down hard and it wont move...
So its not too thin.
And no i dont need to start a new one...
Dang... It was such hard work to do this...
Ill take pics once patched up.

Thanks for the advice guys.
I actually want to get it welded by engineering and then regrind that part.
Im scared epoxy might wear out over time.
I never used it before.</div>

No one was being negative, stop being so defensive. I8acobra and hamhead are exactly right. You say you aren't mechanically inclined, but know how thin to go... No, you don't, as you obviously CUT A HOLE IN YOUR IM. LOL

Of course though, you pushing with a finger is equivalent to the same stress it'll get as you bounce down the road at 80 MPH, right?

You are right, you don't need to start over, you'll get a new one for free with your new engine when this one loses some pieces that get sucked into your engine. Just start over with that one.

<div class='quotetop'>QUOTE </div><div class='quotemain'>Of course though, you pushing with a finger is equivalent to the same stress it'll get as you bounce down the road at 80 MPH, right?</div>
No, pushing it with a finger is probably a lot more stress that it will ever get 'bouncing' at 80mph or w/e lol