LT1-LT4 Modifications 1993-97 Gen II Small Block V8

Bad day for LT1 intake :(

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Old Jul 11, 2009 | 04:47 PM
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Default Bad day for LT1 intake :(

So I was installing the brake booster screw in portion in the intake that the hose hooks upto and it snapped off! I was so close to completing my 355 LT1 with a cc306 cam and now this happened, should I do the right thing and take the intake off to get it removed and then rethread it with a heli coil or should I jerry rig and JB weld the snapped off portion to the remaining portion in the intake???? Sounds shitty I know but how important is this brake booster thing any how? What's this for and can it be bypassed completely????? It's been 3 months of the car being down and quite frankley I've had it! I swear I have the worst luck ever. What does everyone thing about this situation????? Thanks guys steve
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Old Jul 11, 2009 | 04:52 PM
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Originally Posted by 94BlueZ28
So I was installing the brake booster screw in portion in the intake that the hose hooks upto and it snapped off! I was so close to completing my 355 LT1 with a cc306 cam and now this happened, should I do the right thing and take the intake off to get it removed and then rethread it with a heli coil or should I jerry rig and JB weld the snapped off portion to the remaining portion in the intake???? Sounds shitty I know but how important is this brake booster thing any how? What's this for and can it be bypassed completely????? It's been 3 months of the car being down and quite frankley I've had it! I swear I have the worst luck ever. What does everyone thing about this situation????? Thanks guys steve
Without it, you won't have power brakes. The booster requires quite a bit of vacuum to operate at capacity. Jerry-rigging it is totally up to you. I'd expel all options to fix it without taking the manifold off.
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Old Jul 11, 2009 | 04:57 PM
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So how would you do it keeping the intake on? Do you think If I got some type of tap to try and get it out it would work the shavings in or out, that's what worries me??? Not sure what to do at this point!
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Old Jul 11, 2009 | 04:57 PM
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How the heck did you break THAT???

Honestly, I don't know if they make helicoils in that thread size to fix it...

To repair it you most certainly need to pull the intake manifold. You then need to get the broken off piece out, then retap it bigger and use a proper size fitting...

The brake booster hose is VERY critical, as it supplies vacuum to the booster so you have powered brakes... Without the hose being hooked up properly you won't pull a vacuum and have only manual brakes.

Honestly, if that happened to me, if I couldnt' get the broken piece out cleanly and even witha larger fitting, unless I had a ton of cash in the intake for custom work, I would just get another LT1 intake and start over.
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Old Jul 11, 2009 | 05:00 PM
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is there anything special that your intake has that you dont wanna get another?

i'll sell you the one i have off a 95 for 25.0 shipped if interested.
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Old Jul 11, 2009 | 05:01 PM
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Not sure how it broke, it's a 94 with lots of years of heat stress on it I guess! Hell I got it pretty much all the way in and was still going a bit at the end and then snap, followed by a bunch of Mother this and Mother that! What should I use to get it out or attempt! So for sure the intake should come off then! F***!
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Old Jul 11, 2009 | 05:02 PM
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Yeah I have it ported an polished, plus it's setup for the 58mm BBK Tb that I'm using!
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Old Jul 11, 2009 | 05:09 PM
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Yeah, those fittings don't need to be torqued in at all... Just use teflon tape and make them snug...

Good luck...
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Old Jul 11, 2009 | 05:53 PM
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did the actual fitting snap or the aluminum from the intake manifold?
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Old Jul 11, 2009 | 06:07 PM
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Yeah it was the actual fitting! Ok so I just got the intake completly off! Yeah kind of fast I know, I want the **** back together ASAP. I most likely wont be able to get that fitting any where but the dealership so It will be Monday to even place an order and then a 2-3 days for it to come in. I just want to make sure I can get this peice out. I guess I'm running to lowes to see if I can get a tap/Die set.... Wish me luck!
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Old Jul 11, 2009 | 07:40 PM
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Ok, so got the broken peice out and I'm getting ready to install the intake again for the
3rd time in it's life, lol! Thank god I found another fitting to go in it at Ace Hardware so I can get it up and running without waiting a week to get it in at the dealership! Damn if it's not one thing it's something else! Thanks guys for the advice and all. I'll be posting a start up video one of these days! Hopefully all goes well from this point forward!
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Old Jul 12, 2009 | 07:30 PM
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keep your head up man it will be alright thats how it is with this muscle car love we all have sh*t happens
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Old Jul 13, 2009 | 12:27 AM
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make sure the fitting you got was good enough for automotive applications. some fittings i've gotten from harbor freight can't hold the pressure/vacuum well enough and leak.
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Old Jul 13, 2009 | 12:33 AM
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I would take the time to fix it right, even if it means you must remove the intake. If you dont, you know it will come apart at the worst time. You dont want to f*ck around with brakes.
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Old Jul 13, 2009 | 10:23 AM
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i think he did there black 97 ta m6
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Old Jul 13, 2009 | 11:17 AM
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Originally Posted by Crows93Z
make sure the fitting you got was good enough for automotive applications. some fittings i've gotten from harbor freight can't hold the pressure/vacuum well enough and leak.
What do you mean they can't hold the pressure? If it's made of metal and you use a sealer on the threads, how could it not hold up?
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Old Jul 14, 2009 | 04:17 PM
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It's a brass fitting with the coorect pipe threaded end, It's brass so I installed it with some RTV sealant to be safe and painted it black considering my intake is blake. It looks very sharp. If I could every figure outhow to upload some pics then I would post some pics of the new build! Thanks guys
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