Dauntless Intake Manifold Repairable???

I have a 1967 CJ5 that I'm attempting to rebuild. I am about ready to pull the engine, and was taking off the carburetor when I noticed some problems. Please see attached picture. It appears there is heavy pitting where the carburetor bolts as well as a significant chip between the two fuel inlets. On top of all that, there is a broken bolt that I'm hoping I can drill out (EZ-Out). My real concern is the missing metal between the inlets--is this repairable or should I be looking for a new manifold. I've done some browsing, and it appears that most new manifolds are for 4-barrel carbs, I've read that it is probably best to stick with the stock 2-barrel. How prevalent are these manifolds in salvage yards? Thanks.

 

I would pull it and have it cleaned to see what the real damage is. It doesn't look too bad from the picture, certainly nothing a properly fitted gasket wouldn't mitigate. If, after cleaning, the damage is too much, you can start digging for a replacement.

 

Your best bet will be the classifieds here. Somebody likely has one of these from a junk engine or a take-off for an aftermarket manifold. Not a lot of call for the original iron manifolds.

Not many of these out in the junkyards - when they were in Buicks, they got a 1V as I recall.

 

Have a machine shop run a skim cut on the carb surface, clean the EGR passages with a drill bit, remove the broken bolt and use anti-seize and stainless bolts for the carb and you are ready to go. That chipped are can be brazed easily
That doesn't look that bad at all.

 

can you weld a nut to the top of the broken bolt all the heat will normally free up the bolt

 

Mine looked worse than that. Both bolts in the front were rusted and twisted off. I heated them with a torch and was able to get vise grips on them and they came right out. Then I sandblasted the manifold good where it was pitted, filled it with JB weld then filed it smooth. Like a new one now.

 

Awesome advice! I'm going to attempt to tack weld a bolt to the top of the broken bolt, however it is pretty flush. I'll have it machined.

Robetaylor, I'm interested in hearing how you did the JB Weld. I have a torch, but have never brazed, just cut.

 

Didn't braze, just sandblasted the pitted rust out of the manifold and then mixed up the JB weld and spread it on the pitted area, just like bondo. I let it harden for 24 hrs then filed it smooth. It still had a couple of low spots in it so I coated it again. Waited another day and filed it down flush again, just like you would if you were doing body work.