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Thought I would share some pictures (and a video) of the stages of my latest project.

Manifold Gasket Replacement Album

The pictures of the blue bucket with electrodes are the manifolds being de-rusted via electrolysis. After that I cleaned the manifolds with degreaser, followed by acetone, and coated with POR-15 Factory Manifold Gray.

The gasket set, and stud set came from Kanter. All fit perfectly. The only thing missing from the stud/nut set is the thick manifold washers. I couldn't find those anywhere in the Raleigh area, so I used grade 8 washers, doubled up.

What a huge improvement in how the engine runs. I can only assume that the gasket had been leaking vacuum at one or more of the intakes as well.

Chad

Wow, that came out really, really well. Looks great. I'm interested in seeing\hearing how well the POR holds up over time.

The manifold looks great Chad.

Mark, I've used POR-15, in conjunction with their etching / galvanizing metal prep, on dozens of applications, including several on my Packard, over the past 2 decades and had very good luck with it. I'm located in Utah, where we use a lot of salt on our roads in the winter, so it's definitely been put to the test.

When I have to go to all the rusty work of removing a manifold, especially a long intake manifold, I like to take it down to the local machine shop for a surface dressing.
Just took a 100 year old T-model Ford cylinder head down and machinist took 3 passes to get it flat.

Guys,

Thanks for the feedback and positive comments. Getting the manifolds surfaced/dressed is good advice, and I would have done so, except for my own impatience to get back on the road.

I was thinking about this over the weekend, and honestly the hardest/most frustrating part of the process was putting the fender back on. It wasn't too hard to line up, but some of the screws and studs were a real bugger to get back in.

Does anyone have a source for the thick manifold washers? A couple of the doubled up grade 8 washers have buckled at only 30 lb-ft.

MSC has a wide variety of aircraft-quality extra thick steel washers in many sizes, and no doubt McMaster-Carr does as well. For general industrial equipment MSC in my experience has the widest range of products, and outstanding customer service and delivery.

http://www.mscdirect.com/

And if MSC or McMaster doesn't have something, Cli55er found another option he went with for his 55 engine.https://packardinfo.com/xoops/html/modules/newbb/viewtopic.php?post_id=93555#forumpost93555

Thanks for the links and hints for the thick washers.

Now that I got a little prodding, I am finding them all over the place. There are many suppliers to choose from, with lots of options in 3/16" thick, some even as thick as 1/4".

Edit 6/10:

I wound up ordering these: 3/8 x 1" x 3/16 thick washers from Amazon.

Thanks,
Chad