I've been wanting to clean up the intake manifold on my PV544 with the '75 B20 engine for quite a while now. I finally got around to buying a manifold gasket, so yesterday I removed the carburators and intake manifold to do some major housecleaning.

I haven't touched the carbs yet, but I already know I have to rebuild the front one because someone put it together using the wrong springs and jet. Luckily, I have a big supply of parts, and I think I can remember how to do it, although it's been ages since I had one apart. I bought the English S.U. manual in case I forget something. :-)

Tuesday night I blew out two of the nickels that were used as plugs for the fuel injector ports, so while I'm making a permanent repair of that mess, I'll just go ahead and clean up the right side of the engine.


Here's a picture with the intake manifold removed. I also removed the linkages and cleaned, sanded, primered, and painted them to match the body color.


I've filled the unused injector ports with JB Weld and metal disks.
When the compound dries (tomorrow)I'll sand it flat, then fill any imperfections with bondo, ready for paint.


This is the intake manifold in its rough form. Take note of the cast-in numbers and letters, and the big unused boss in the center.


About 1/2 way through the polishing routine. The numbers and letters are gone, as well as that unsightly boss.

To get it to this stage, I used a 4" angle grinder with a cutting blade. I used the side of the blade, like a grinder. The fine grit of the disk was gentle with the soft aluminum. The entire surface of the part was pitted from the sand casting process, so after the grinding was done I chucked a medium grit sanding disk into the grinder and worked as much of the surface as I could reach.

I changed tools and brought out my small oscillating sander, with 80-grit paper it it. I could reach a lot more places on the manifold with this, and it had the added advantage of 'planing' down any high spots.

To finish the day, I finally went to emery sticks, starting with the coarsest one I had (about 100 grit), getting rid of the marks left by the grinder and sander.

I have two more - finer - grits of emery board, then I'll finish up with three different rouges on a linen buffing wheel. The end result should be a gleaming silver-like shine.

The only problem I've had is trying to get all the nicks and dings out of the metal. It looks as though someone used a hammer on the manifold, then used it as a hammer. Only time and elbow grease will get rid of these dimples.

Tomorrow's forcast is for sunny and 75 degrees, so I should be able to finish up the manifold, and hopefully the linkages, engine painting, etc. and be ready for the cruise on Saturday morning.

Steve