Reckless

iTrader: (9)

Well, the direct port kit isn't here yet, but I got the install of the intake part written up here:

Intake Install

Fuel System for Direct Port


Questions?

Elite_Hot_Rod

Nice job Todd,

First off, I would probably and did use countersunk allen head screws for both the access panel and the valley pan, you may still have clearance issues with those button head screws. I would temporarily put the manifold in place and check the valley pan for signs of contact with the screw heads before you button everything down, wish I had. I would also check the shoulders(washers) of the head bolts for protrusion into the manifold to head mating surface,when I installed mine the head bolt washers were sticking out just far enough to keep the manifold from fully seating, you may need to grind some of the washer radious off. Take a look at your manifold gaskets and see if there are any signs of the gasket being rubbed or worn in that area. Last but least, before reinstalling the LS1 valley pan I would consider going with an LS6 valley pan. BTW, I'm going back to an LS6 manifold, I do spray but not with a direct port kit.

Mark

Reckless

iTrader: (9)

Thanks Mark...I started the car last night and definitely have leaking. I will have to take another look at things to see what the culprit is.

Todd

Elite_Hot_Rod

Todd,

I'd be interested to know what you find.

Mark

Reckless

iTrader: (9)

You had it right Mark. I used a flashlight and a small mirror to peek under there, and sure enough I could see the small bolts from the intake cover were bottomed out on the valley cover.

Pulled everything off and used my 1/2-inch drill bit to make 10 "clearance" depressions for the bolts. I also bought some bolts with a different head. Then I just decided to seal the thing with silicone using the bolts to let it set up over night. I will then just install it without the bolts and let the silicone hold it on. Hopefully everything clears this way.

I take it the LS6 valley cover is a lower profile? Holley needs to get their **** together on these intakes. What a PITA for a so-called bolt-on <img border="0" title="" alt="[Roll Eyes]" src="images/icons/rolleyes.gif" />

Todd

Elite_Hot_Rod

Todd,

Glad I could help unfortunately I didn't chime in before you got it put back on. LMAO, "PITA" you got that right. Keep me updated, did you dyno before you installed the Holley? I'd like to see what the results are. I gained 7 RWHP's over the LS6 manifold but think I may suffer some after 3 passes due to heat soak. Let me know how it's goin.

Mark

DONAIMIAN

iTrader: (18)

Keep us posted, I cant wait till you get the pics of the direct port <img border="0" title="" alt="[Wink]" src="gr_images/icons/wink.gif" />

Reckless

iTrader: (9)

No sweat Mark....did sacrifice an oil pressure sensor in the process though. Just waiting for the rest of my parts to arrive.

Have most of the fuel system parts and will start on that soon and update the page.

Todd

Elite_Hot_Rod

Todd,

I think I was probably one of the first in the country to install the holley manifold so it was all trial and error, that was really frustrating. I had to call Holley tech support a couple of times. I bet we had that manifold on and off at least 6 times before everything worked out right. First we just installed the manifold and it leaked. Then the access panel screws were contacting the valley pan, ground them down and it still leaked. Then we saw that the manifold was actually resting on the heads of the valley pan bolts, so we countersunk the valley pan screw holes and used countersunk allen head screws and it still leaked. Then we noticed the manifold gaskets had real small tears right where the shoulders on the inner head bolts are so we ground those off and it finally sealed. 6 times? OK, I guess I was exaggerating alittle but 5 times is enough. We never broke the oil pressure sending unit though, probably just got lucky.That thing ought to rock as a fogger, best of luck and let me know what kind of numbers you put down and how it does at the track. Your going to get some attention at the track, I do. Most of them say look he's got that POS Holley manifold, I don't say anything until after I drag them down the track then they usually just give you a dirty look.

Mark

Reckless

iTrader: (9)

That's funny. Yeah it has a bad rep for sure. Already fending of the "that thing is a heat sink" crap from people. My usual response is something like, "But it'll be nice and cool with lots of nitrous flowing through it!" Then they shut-up <img border="0" title="" alt="[Big Grin]" src="gr_grin.gif" />

Todd

Q

iTrader: (18)

Hey guys quick question...what could I use to cut open the bottom of the intake for better access to the runners?

Thanks,

Q

Elite_Hot_Rod

Q,

You could ask Jeff(BADZ,Texas section)exactly how they did it. I think he had Craig at GTP open up the access plate area on his. I think Y2khawk(Harlan,forced induction section) did some custom runner work on his also. I would imagine they just chucked it up on a mill. You could cut it out using a high speed cutting wheel and a die grinder, either way you would have to manufacture a replacement cover plate.

Mark

Beeler422

iTrader: (3)

I have several pictures on my webpage on installing the holley intake and the grinding required on the LS6 valley cover. Look under motor pictures.. www.zero-hp.com

Q

iTrader: (18)

Thanks for the reply guys. Beeler I looked at your site, nice ride. I'll probably try to cut it open using a grinder/router or something and then making a plate from the sheet metal at Homedepot.

Anyway, I'll only lose $100 bucks if it doesn't work correctly.


Q

BADZ

iTrader: (5)

Q, Craig cut my access hole out with a Bridgeport mill and had all the custom port work done in his shop (all smooth as glass port work in runners). Then he sent it out to be polydyned for the "heat sink problem" which that coating acts as a barrier against all heat transfers...Coated the exterior of the intake also...Me and Steve had to make another plate because the one Craig made was to think and had to much interference with the valley head bolts so we went with some sheet metal .0625" (drilled the holes)and laid it in place as it fitted up flush to the already machined offset that was done on the intake and there were no more clearence issues at all...

A grinder wheel should do o.k. just take your time...
<img border="0" title="" alt="[Smile]" src="gr_stretch.gif" /> <img border="0" alt="[cheers]" title="" src="graemlins/gr_cheers.gif" />

Beeler311 sent you a PM.

</font><blockquote><font size="1" face="Verdana, Helvetica, sans-serif">quote:</font><hr /><font size="2" face="Verdana, Helvetica, sans-serif">Originally posted by Elite_Hot_Rod:
<strong> Q,

You could ask Jeff(BADZ,Texas section)exactly how they did it. I think he had Craig at GTP open up the access plate area on his. I think Y2khawk(Harlan,forced induction section) did some custom runner work on his also. I would imagine they just chucked it up on a mill. You could cut it out using a high speed cutting wheel and a die grinder, either way you would have to manufacture a replacement cover plate.

Mark </strong></font><hr /></blockquote><font size="2" face="Verdana, Helvetica, sans-serif">

Beeler422

iTrader: (3)

My intake already had a hole in the bottom of it with an access plate covering it. Did y'alls not come that way??? Since the pictures, I also ported and poished all my runners and the inside of the intake. Wish I had taken pictures but I forgot. BADZ, Send you a reply.

Beeler422

iTrader: (3)

Also, I had to grind off all but two of those bumps on the top of the valley cover, as well as countersink the screw in the access plate to make it seal. And cut a notch in the intake where the PVC thing is. You can see all this in the pictures.

Beeler422

iTrader: (3)

Nevermind, I read it again and understand now. You meant you opened the hole even more. (I think <img border="0" title="" alt="[Smile]" src="gr_stretch.gif" /> )

GrannySShifting

iTrader: (10)

Putting your intake on kinda sucked didnt it Jeff <img border="0" title="" alt="[Smile]" src="gr_stretch.gif" />

Reckless

iTrader: (9)

Updated the links in first post...split up the intake and direct port stuff.

Todd