Aluminum intake with stripped threads

[kennyw]

I picked up a 1978 Chevy C20 a while back. The carb on the motor was a manual choke Holley without the choke hooked up and it had some issues.




Rather than rebuild it, I decided to swap it out for a rebuilt Quadrajet I already had on the shelf with an electric choke. After removing the carb and adapter, the first issue was stripped threads on the intake. Note at least one broken/stripped helicoil from a previous repair.




I found some inserts that stepped up to a 1/2-13 from the original 5/16-18. So a quick drill and tap later, I was able to install the inserts. The biggest trick was using a vacuum while drilling and a little bearing grease on the tap to help trap the shavings.



After that, the new carb bolted on without issue and it was time to run a new fuel line. I used a piece of aluminum wire to make a template. Then, bent the new line into shape. It was close but needed one final tweak at the last bend and I kinked the line. I'll need to grab another line tomorrow and try again.

 

[Wes Harden]

Looks good, yes grease on the tap is great way to collect the clips. Technique I used repairing 100's of furd Triton spark plug threads.

Nice bending job, looks really close to factory.

I hope that remain Q jet runs good, always disappointed when I see the gold coating is gone.

 

[kennyw]

I've had decent results from the company I bought this Quadrajet from in the past but I think they replate the carbs before they rebuild them.

 

[Wes Harden]

It does look like it has had a shellacking

 

[ktmoutfront]

Pack the tubing full of really fine wet sand. Do not just pour it in. Pack it as you go. Keeps the kink to a minimum. Just be sure to completely flush it prior to install. I made caps for the ends by brazing a couple of female fittings closed, to hold the sand in. Works like a mandrel in a bender.

 

[kennyw]

I finished remaking the new fuel line again, replaced and rerouted the ground cables correctly, and put a new end on the positive battery cable. It fired right up then immediately flooded and started pouring fuel out of the top. I'll have to take it apart tomorrow and check the float and needle valve.

 

[tRustyK5]

Another trick is to use a spiral tap, because it drives the chips up and out rather than down and in...

 

[kennyw]

Nearly done other than the choke wire. Waiting for that pigtail to arrive Tuesday. View attachment 20230107_141436.mp4

 

[kennyw]

I replaced the carb with another rebuilt carb a friend had in his shelf. I'll deal with the other one later.

I ended up replacing the upper radiator hose and thermostat housing after that video to fix the coolant leak. It had the wrong thermostat housing pointing straight ahead rather than to the driver side.

 

[ramack]

Nice job, good pics!

 

[kennyw]

I sold this one a while back and it ended up getting totaled. I'm planning to run down and buy it back for the drivetrain next week.

 

[cheavyk10]

It also made my band's album cover....

 

[kennyw]

Got it home this evening. It still drove up on the trailer but the rear is tracking 8" to the right of the front.