I'm cleaning up my intake manifold on my 1998 F-250 4.6L romeo. It is the solid aluminum one. I'm wanting to paint it and make it look nice to go with the engine I'm rebuilding. The steel water intake tube from the heater core that goes into the back of the manifold was pretty badly rusted. Getting it out was a HUGE chore. Apparently, they are pressed into place ... I suspect with some sort of bonding agent. I had to use a Dremel to cut the sides of the tube in the hole to get it out. I did bump the bare sides a bit with the Dremel, but not too bad. I saw another post that suggested welding a thick walled aluminum tube on as a replacement. However, I see that you can pick up an aftermarket one on eBay for about $25.



If I went that route, can anyone suggest some sort of bonding agent that would make a good seal?

Thanks,
Steve
Kissimmee, FL

 

I'm thinking of giving JB-Weld cold weld a try. The specs don't look too bad.

 

Apparently, Dorman makes one of these heater core "bypass" tube/pipe thingies and RockAuto has it for just $15. Sweet!