I got my PSR from Naz this past July, I think it may be the one of the last he made. At the end of this season I started getting lean codes and would simply clear them and keep driving. Didn't see anything obvious and since I am planning on building the motor, didn't care much. I initially decided to sell the intake for the new build but after seeing the cracks, I pulled it from the market and will now repair/improve it. The cracks clearly are where the lean codes came from. I didn't grab a picture of the cracks in the PSR as assembled but here are the main ones after I removed the bottom of the intake...
There were other cracks in the weld which propagated from an area where the weld was likely thin. The bottom metal is so thin that I think getting a good weld on it is not likely. Also, the metal is not soft enough to give, not sure what it it but it doesn't look like 6061.
Here's the inside of the PSR unmodified..Notice the ends have abrupt transitions from the endcaps to the intake and the corner runners are a bit rough in transition. There is also a lot of epoxy build up in a couple of the runners not visible in these shots.
I did some smoothing and added JB weld to smooth out these areas, will finish them off later...
Also removed a lot of epoxy that had created a large obstruction in this corner runner..
before
With the epoxy smoothed out, the transitions from the bell to the runner are really good...
I cut out a new bottom from 6061 1/4" thick..
Comparing the old with the new bottom...
and the fit...
It will go a the shop next week or two to be fully welded by a certified AL TIG shop. So far, I'm into this repair about $70 with some consumables and the Aluminum plate. We'll see what the welding will cost but in the end, it will be a better intake. Not sure if I will sell it or not after this work/expense but thought ya'll might enjoy seeing what I've been working on lately....
There were other cracks in the weld which propagated from an area where the weld was likely thin. The bottom metal is so thin that I think getting a good weld on it is not likely. Also, the metal is not soft enough to give, not sure what it it but it doesn't look like 6061.
Here's the inside of the PSR unmodified..Notice the ends have abrupt transitions from the endcaps to the intake and the corner runners are a bit rough in transition. There is also a lot of epoxy build up in a couple of the runners not visible in these shots.
I did some smoothing and added JB weld to smooth out these areas, will finish them off later...
Also removed a lot of epoxy that had created a large obstruction in this corner runner..
before
With the epoxy smoothed out, the transitions from the bell to the runner are really good...
I cut out a new bottom from 6061 1/4" thick..
Comparing the old with the new bottom...
and the fit...
It will go a the shop next week or two to be fully welded by a certified AL TIG shop. So far, I'm into this repair about $70 with some consumables and the Aluminum plate. We'll see what the welding will cost but in the end, it will be a better intake. Not sure if I will sell it or not after this work/expense but thought ya'll might enjoy seeing what I've been working on lately....
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