Is cracked intake repairable?

[jmc1590]

Hey all,
Quick question: I've picked up a '91 TSi that has a few issues. When giving the engine bay a quick once over, I noticed that there is a small chunk missing from the intake manifold, approximately in line with the upper / forward bolt - stud mounting the TB. There appears to be space behind it. If the missing piece has exposed the intake to air, then I've got a vacuum leak that needs to be repaired.

I have some metal work experience and have TIG equipment at work. Does anyone know if the stock manifold is repairable, or should I consider it a lost cause and search for a replacement? If repairable, what filler material should be used?

Thanks,
James

 

[GRAVEDIGGER]

So is it really leaking, or it just looks like it might be? A boost leak test would verify whether or not it's leaking. Does the car run okay, or does it have issues?

 

[dsmcrzy]

You might be able to fix it depending on the size, but for piece of mind I would look for a new one. The last thing you want to happen is that piece blow off and be back where you started or get sucked into one of your valves. People sell aftermarket nice intakes on here all the time just check the classifieds.

Good luck!!

 

[doubled07]

I would boost leak test the system. If it does not leak i wouldn't worry about it. If the piece leaks you could attempt to repair it. If that doesn't work you can purchase a new one. I think I have a stock one. PM if you need it.

 

[nitrouskris]

you should,

 

[jmc1590]

Good ideas. I'll be running a boost leak test tonight. Which leads to a related question: How much boost? I may not have said it in this thread, but I have no idea yet exactly what was done to this car. A couple things I've noticed - The mark on the SBC boost controller is at 22. Is that a reasonable # for boost? (From my short test runs, I've gotten to 8 psi, then backed off as knock went nuts.)

I'll see if I can get a picture of it tonight. A smoke test may also help find vacuum leaks...

James

 

[phunny]

Here ya go, like $40 shipped. It's not anything special but it'll work for you.

90 91 92 93 94 EAGLE TALON INTAKE MANIFOLD | eBay