Inliners International Forums General Discussion Engines Offenhauser Upset! AGH!

As some of you may know, I was in the process of putting together an offy 3x1 setup on my 72' Nova 250. I had everything done, new radiator, water pump, hoses, belts, fuel pump, custom bent hard-fuel line, carbs, intake, Langdon's headers, custom fabbed linkage system... ect.

We were putting coolant in, and high-fivin "yes! its finally assembled!" And in the process, coolant filled up the water jackets of the water-heated offy intake. And then we noticed a sizable leak and were like, "oh great". so we wiped up the excess coolant to locate the leak. And to my dismay it was coming from the little "smooth" plugs, which I think are offy cast expansion plugs. I couldnt believe it. I then, despite the steam shooting from my ears, disassembled EVERYTHING, and found, yes, that IS where the leak was.

Now, my instructor and I were thinking about drilling a hole in each plug, and pulling those out, to put in real brass freeze plugs meant for heads/blocks. But I dont know how well that would syn with an aluminum intake.

Help! I need a little guidance! ASHFDkjasldf!!$%@#$

How big are the plugs, and what material are they made from? If they're cast aluminum as well, why not TIG them shut? Good luck!

Take out the metal plugs make new ones and have someone Tig Them into the intake. Or simply TIG the Holes up.

The Offenhauser Intakes with the aluminum plugs were never meant for coolant heat only exhaust heat.Why sellers don't explain this,with the exception of Tom Langdon,I'll never know.I can't count how many times ,even on this board, I've read of this problem.I nearly experienced the same problem, but somebody on Inliners saved my butt from a mess.

You are on the right track - use aluminum slugs.

Here is how a fellow stovebolter did it:

http://rides.webshots.com/album/548884102dDFYIH

You can also Tap it for a Pipe Plug Just make sure you have sealer on the threads.

UPDATE:

I pretty much did the same thing as shown on that website, however, do to my & my shop's inability to weld aluminum, I used a bead of JB Weld before placing the new plug in, and around the top seam. It should definatly not leak now.
I know it looks ugly now, but a little sanding a a touch of VHT will cure that. And yes, I cleaned and smoothed out the plug seat before reinstalling the new plugs.

Wait! That screwdriver isn't rusty enough!

Ed is a super nice guy too. He sent me some of these in the mail once and guided me thru it!

FINAL UPDATE:

After finally getting the car to start and run a little, I got it nice and hot, and once again checked for leaks. And the new plugs and layers of JB Weld seem to be holding, and I could not find any coolant seepage anywhere of anykind.

Some more testement I see of the POOR

Oops... ..I was saying..POOR quality of Offenhauser products this day and time. My new intake is off 1/4 inch front to back. Lay a gasket on it and the ports want even line up with the gasket....SCRAP

SCRAPIRON I.I. #4711
Active BB Member
Member # 1581

Rate Member posted 04-03-2007 03:16 PM
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"Oops... ..I was saying..POOR quality of Offenhauser products this day and time. My new intake is off 1/4 inch front to back. Lay a gasket on it and the ports want even line up with the gasket....SCRAP"

Are you sure you don't have a Holden intake??? Aussie GM. close in design but closer between the ports. If you bought it new contact Offenhauser.

Over all size is OK.. The rear hole is drilled 1/4 inch off up and down. When I slotted the hole to line up ports then all the ports were cocked about 10 deg. With some port matching I will be able to use it. My friend got a new set of Offy FLAT HEAD ford heads that were so poor that he returned them. He was told that the Offy stuff was being made in Mexico now. Now this is hear-say..I have no facts. Just makes sense to me. There is no reason that my intake was not flagged at the plant if they have any type of Quality Control...SCRAP

Maybe I should be looking for a Clifford 4bbl intake rather than an Offy then., This is helpful folks.

I have an OFFY that was on the car when I bought it in 89 and it fits just fine, maybe they did chhange manufacturing. There is no water cooling on it.
Terry

Same here.

I got mine (4bbl) on e-bay & It's been used and there's no gring/file marks on it. The holes are untouched also and the gasket marks are in the "right" (alingned) position(s).

Hopefully; They'll get enough returns to "clean up their act".

Happy trails.

Hmmmm, My Offy intake came from Summit packed in the original box from the factory. They used balled up pieces from the "Los Angeles Times" to fill up the "pockets" around the intake, so I doubt they are manufacturing in Mexico, unless they go through the expense of sending old LA Times to a Mexican plant. The inspection tag from the factory quality control reads "Date of man. April 2005". Also, I had no issues with ports lining up correctly.

I have come to the fact that my holes were drilled wrong. After slotting the holes (front a little bit and rear a bunch it fits square) I will take it to a friend and weld them up and drill them in the proper place . If there is a bad part anywhere I will always get it.....I bet they are not packed in Mexico !!! SCRAP

OldFartEd is neither old or a fart. In fact he is a very talented metalworker and a Stromberg 1bbl wizzard willing to help the less inteligent.

'250Nova'
If your JB Weld gives you any problems let me know. I would weld some slugs in it for you, only cost to you would be shipping charges from Illinois back to you. I still have a half dozen or so more aluminum slugs.

And '52pu', wow, thanks for the complements. I'll try not to get a big head. (ha) Life's to short not to help others. Thanks !

UPDATE

It's been driven countless times since completion, getting up to temp and back dozens of times, and no leaks as of yet.

i have an offy dual intake for my plymouth flathead, not problems watsoever with the craftsmanship,

i seem to remember it having a "made in USA" tag on it but with labor costs going up manufactoring costs have to go down, so that doesnt always stand for the best quality anymore =/