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So I have a c4 with an ls6 I recently swapped. I haven't driven it out of my neighborhood until today. That's because I didn't have an exhaust and was just running open.
Today I went to get the pipes installed and after about 6 miles of very loud, but gentle running....it got very rough.
I was hoping that it was just not enough back pressure was messing up the o2s. But it turns out I had a crack behind the throttle body
1. Which is chicken, which is egg? The crack or the rough running?
2. Was this most likely cracked when I got it 6 months ago, and I just didn't notice until it heated up?
3. Anything else to check?
4. Can I just solvent weld this, or is the intake toast?
intake cracked and caused vacuum leak and rough running. No idea if it was pre or post install. I would say you definetly could seal it up. Jb weld or some kind of epoxy.
I would drill it then look for epoxy that BONDS to Nylon 66 which is what he intake is made from. Theres a link somewhere on here in a diy thread for fixing one its 25 bucks a tube but the fact is ts the only thing made to bond to that type of plastic. You could plastic weld it but you would need a peice of scrap from another ls intake
There are a couple threads on plastic welding nylon 66, including a video here. Probably best bet, followed by epoxy. I always drill the end of cracks to prevent them from starting again.
You can get nylon 66 black tie straps from harbor freight & many places. Not 30 percent glass filled like the intake, but still suitable for welding .
Donor engine likely got hit in front OR manifold separately took a hit it wasn't designed to take. cracked didn't likely happen on it's own. Rear vacuum connection is another fragile area.
I recently repaired mine by plastic welding it with a butane soldering iron pen.. gets real hot melt the crack fill with nylon zip ties & cover with epoxy.. Mine was much worse, on the rear map sensor spot whole thing broke off.. Its good now..
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Ls 6 intake cracked! 
