New aluminium intake

This area is for those who need help modernizing their Lincoln for purposes other than strict restoration. Such questions can be about adding an electric fuel pump, adding fuel injection, boosting horsepower or gas mileage, or tightening or lowering the suspension. Body customizing and chopping can also be here (although this practice is not encouraged by the LCOC).

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New aluminium intake

Postby denizen44 » Wed Apr 26, 2017 8:14 pm

An intake manifold has been on my wish list for quite some time.
Should make a nice upgrade! :whistle:

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Edelbrock performer 2166.
For the modest kind of RPMs a Lincoln is likely to do. :lol:

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Noyce!

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Also got some new radiator hose, a thermostat gasket, some brake parts cleaner...
And of course the best RTV product I could find.

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Intake gasket (Edelbrock 7223) should arrive tomorrow.
Never installed an intake before, so of course I may post further questions/issues when I start.
Last edited by denizen44 on Wed May 03, 2017 4:29 pm, edited 3 times in total.
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Re: New aluminium intake

Postby denizen44 » Thu Apr 27, 2017 10:24 am

First question:

What is the typical method for "unsticking" the old intake?
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Re: New aluminium intake

Postby JimA » Thu Apr 27, 2017 1:39 pm

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Re: New aluminium intake

Postby denizen44 » Thu Apr 27, 2017 8:43 pm

Took away the carburetor and all its connections(fuel, choke, kickdown, PCV, advance and throttle), plus the coil and throttle cable bracket.
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Distributor is out, I carefully marked it to remember its previous position.
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Thoroughly cleaned up the the distributor gear area...
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Thermactor pipes were in the way so they're off for now...
Water inlet out... Also rigid fuel line extending from below, at the pump...
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Plugged the fuel pump for cleanliness...
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Of course, the old intake wouldn't budge.
This is how I 'unstuck' it:
by forcing in a segment of the end-gasket made of cork, to insert a pry bar.
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It wasn't so hard to dislodge after all.
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I had to work alone, but this old carb spacer helped me build an improvised 'crane' to help support the heavy part.
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Oohh.. This is my first time seeing such a valley.
These old gaskets are still in very good condition. One could 'almost' think they can be re-used...
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More detail before scraping.
Used mostly a scraper, and then a flat chisel worked wonders on the tough areas.
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While cleaning up.
I made damn sure not to get any gasket scrapings anywhere!
My best friend during this entire operation: shop vac!
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The surfaces are very clean. Used brake cleaner.
I also used a tap to clean the threads.
Then I put the studs back in place with a small amount of Permatex copper anti-seize compound.
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Edelbrock 7223... It features a pre-applied silicone bead around each opening! Neat.
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New gasket in place for a dry run...
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Ah, nice.
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One can clearly see the end gap...
A 1/4 inch RTV bead should be fine...
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The old one. Heavy bastard!
The new one is 36 pounds lighter :D
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My current problem: this old fitting won't budge.
Used lots of strength, to no avail. I fear it may brake if I insist.
As a last resort, I may be obliged to have it heated up....
But first I'll just try to find a new one.
Image
Last edited by denizen44 on Thu May 10, 2018 5:16 am, edited 12 times in total.
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Re: New aluminium intake

Postby Dan Szwarc » Fri Apr 28, 2017 7:36 am

Bigger pipe!
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Re: New aluminium intake

Postby denizen44 » Fri Apr 28, 2017 8:28 pm

Day three! :roll:

Dayum, it sure takes a long time to finish this job.
One could easily think it should only take 3-4 hours... But so many LITTLE things are very time consuming.

This new fitting sure is pretty, but it takes a week to get here, and sets me back at least another $50, nothx.
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Good thing I managed to unstick my rare oem STEEL fitting; blowtorch heat did the trick.
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This is some of the intake hardware.
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A plug. For the coolant hardware, I used teflon tape.
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Manifold vaccuum. For the air hardware, I smudged a little silicone on the threads.
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This water fitting came with the intake.
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Most is done.
No, I'm not aiming for prettiness.
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Lay a thick bead of RTV silicone, and also apply some around the coolant passages.
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I smudged a little on the intake as well.
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It's down!
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Did the torque sequence in 3-4 steps. 25 lbs in the end.
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So many clamps to tighten.
Had to change all the coolant hoses, a good example of time-consuming side-tasks.
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Back to the carb.
If I keep the previous configuration, that infamous OEM spacer will give me the same problem as before!

(see this older thread)
Serious vacuum leak under here!
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The OEM intake had a flat support for that entire spacer. But NOT this edelbrock.
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I'd gladly ditch the fragile spacer and use the Carb's PCV opening instead BUT, because it is slanted , it is necessary to keep the carb leveled.
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The Moroso 64930 1"spacer could make a nice workaround, providing a flat support for the OEM spacer.
I'm already using a 1" phenolic spacer anyways, just not THIS ONE.
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But.... I just happened to have a solid block of nylon lying around... that could make a nice custom support. 8)
The trick is to extend my 1" phenolic spacer with the nylon block, and then put the OEM spacer above that.
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I made a small surgery on the old gasket because it was slightly overlapping.
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Drilled, to hold it in place.
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Upside down view of both spacers: should be strong!
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Can't quite see it, but there is also a lock washer behind these nuts.
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Topside: the gasket and nylon block are perfectly aligned.
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Should be fine!
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The new manifold vacuum opening is vertical but I made it horizontal like the original, with a new elbow fitting similar to Edelbrock 8179.
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Next, looks like I'll need to fabricate some kid of bracket for the coil...
Yet one more thing that's different on this new intake! :smt013

Sigh. At least tomorrow I should be ready to install the carb, at last! :D
Last edited by denizen44 on Sun May 19, 2019 8:39 pm, edited 19 times in total.
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Re: New aluminium intake

Postby TonyC » Sat Apr 29, 2017 5:06 pm

Nice, for someone who isn't looking for pretty.

I'd advise some thread-lock sealant on those screws for your nylon block, to reduce the chance of the nuts working themselves loose down the road.

---Tony
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Re: New aluminium intake

Postby denizen44 » Sat Apr 29, 2017 5:08 pm

Alright, day 4 ! :roll: sheesh...

First time using these gasket types,
I hope this is the correct choice.
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Then, modified 1" spacer
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Then, the slightly trimmed 4-hole gasket.
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Then, slanted OEM spacer
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Then, another 4-hole gasket
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Carb is in!
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Another angle.
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The custom spacer fits perfectly!
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Also reconnect the coil...
Turns out the old bracket fits just fine. :D
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Now for the distributor.

First, oiled up the gear...
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But then, no matter how I lowered it, it wouldn't go in all the way.
I could feel the gear engage but from ANY angle, there was always about 1/2" left to go.
Messed with it for 15 minutes, to no avail.
It's definitely hitting something hard, but what?
Almost NO friction when I rotate the distributor, so I ruled out these frame rings as a source for the blockage.
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It has to be that loose shaft in the middle.
It's for the oil pump, or so I learned...
I first thought it was off-center but that's not the problem.
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The distributor shaft turns the hexagonal oil pump shaft like a socket.
At this point it can only be one thing: that shaft down there must be misaligned.
Because it's not super easy to turn, it cannot be "shifted into position" by gently tapping on the distributor.
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Someone on another forum pointed out that indeed the oil pump shaft must be dialed to the right angle before the distributor can go down.
Careful exam of the distributor shaft revealed it was... 8mm
This socket is the correct size but I
DID NOT want it to fall down there....
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A long tool to lower it down.
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Trial and error, I had to spin the shaft a few times.
Once the shaft was aligned, the distributor immediately went all the way in, like a champ!! :D :D :D
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Next up I reconnect a few things: choke, kickdown, throttle, fuel.
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Then the air filter housing.
Turns out, the new intake is TALLER than the original, so I had to SHORTEN the the air filter bolt 1/2 inch...
Good thing I didn't slam the hood before I found that out ( :wink: to 2sasilverbullet).

Then started the car up.
IT RUNS... yayz! And no leaks!
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But there's a small problem:
If I let go of the gas, the engine starts idling roughly and stalls.
When I got the choke on a little, it runs.
When I keep it above 1600 rpm, it runs.
Release the gas pedal... Stalls.
it just won't idle!

It's probably the carb adjust at this point... Strange, it used to run perfect and I changed NOTHING on it.
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I'm not sure what to do.
I tried unscrewing the idle screws 180 degrees.
Not much change so far.
Ideas about what happened?
Last edited by denizen44 on Sat Jun 03, 2017 2:50 pm, edited 21 times in total.
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Re: New aluminium intake

Postby defrang » Sat Apr 29, 2017 6:03 pm

Thanks for posting such an awesome photo essay of your intake manifold replacement etc. Its just like being there without the headaches and problem solving. Hope its dialed in soon.
Rob
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Re: New aluminium intake

Postby JimA » Sat Apr 29, 2017 6:16 pm

Recheck all your vacuum connections. Or, disconnect them one at a time to see if a vacuum leak can be located.
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Re: New aluminium intake

Postby denizen44 » Sun Apr 30, 2017 7:19 am

Started a carb thread.

Edit:
at last, all carb problems solved!!
:smt033
Last edited by denizen44 on Tue May 02, 2017 6:51 pm, edited 1 time in total.
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Re: New aluminium intake

Postby Steve K » Sun Apr 30, 2017 8:19 pm

You are lucky that banging that dizzy around trying to get it in didn't dislodge the oil pump drive shaft and let it drop into the pan. Now that is another fine mess no one should ever have to pull a pan for. Ask me how I know.... x 2 on different cars. :naughty:
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Re: New aluminium intake

Postby denizen44 » Sun Apr 30, 2017 9:29 pm

Gaahh, The horror! :o

But I dare ask how you know.. If you want to share.
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Re: New aluminium intake

Postby denizen44 » Wed May 03, 2017 6:44 am

TonyC wrote:I'd advise some thread-lock sealant on those screws for your nylon block, to reduce the chance of the nuts working themselves loose down the road.

TonyC, thank you so much for pointing that out.
DESPITE the locking nuts, you are absolutely right. Had those nuts managed to work themselves loose, they could have fallen into the engine! :o
For this reason I have filled the relevant chamber with silicone, plus reworked the 1" spacer to be installed upside down, making it impossible for this scenario to happen. :D

Image
Last edited by denizen44 on Wed May 10, 2017 9:10 pm, edited 7 times in total.
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Re: New aluminium intake

Postby TonyC » Wed May 03, 2017 2:10 pm

:smt023 :smt023

I'm sure other 460 owners would want to follow your lead. I wouldn't want something so small to cause catastrophe for you.

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