The install tip I was going to offer to him is probably well known to most of you guys, and if not, it'd still be common sense to most decent mechanically inclined guys. Heck, maybe he already tried it. If he did, then it proves that the machinist is the weak link here.
ASSUMING MANIFOLD IS SERVICEABLE:
1) Disassemble, inspect, clean, and reassemble with new, high quality mating gasket.
2) Plane mating surfaces true. Install new studs as necessary.
3) Upon installation, loosen bolts that mate intake and exhaust so the two are not rigidly mated.
4) Clean all mounting bolts, studs, nuts thoroughly before starting. Chase threads with a proper die and use a bit of anti seize on newly cleaned and chased threads to aide in ease of installation.
5)Mount assembly to head starting all bolts in the head by hand (not with a wrench or ratchet as this can encourage cross threading ) generally working from the center port toward the ends. Tighten clamping bolts and end bolts finger tight. Then, and only then, snug the mating bolts back up.
6)Put initial cold torque on head bolts according to the manual, and then initial cold torque on the mating bolts.
7) Run vehicle, do secondary torque after it's warmed up.
If this sequence does not work, then the machine work is most likely the culprit.
Last edited by BlueChipper; 10/18/2016 9:07 PM.
