[Jim Hand]

Jim M.
When we reference aligning an intake, we mean to do whatever is required to transfer maximum amount of air flow through the intake into the head. Some folks talk about "gasket matching", but that can be very misleading. In all cases, the intake gasket should be used as a reference when working both the heads and the intake.

The following may not be practical for engines with special intakes, matching numbers, special originality, or other such concerns. It is applicable to any attempt to obtain maximum performance from our engines.

Whether "ported" or not, the port openings on the heads should be cut to gasket size after the gasket openings are accurately marked onto the heads, and the openings should be blended into the ports for at least ½", and preferably farther. The same gaskets should then be secured to the intake and centered on the original Pontiac centering/locating holes - the holes that match the head holes that are made for the Fel Pro orange gasket hold-downs. You may be shocked at how badly all intake runners are aligned. It is not necessary to cut the intake outlets to gasket size in many cases, but it is important to move or realign them such that they are within the gaskets openings. Otherwise, the airflow coming through the intake will see a sudden obstacle of the gasket edge, or edge of the head port opening in the flow path. We use normal metal cutting tools, and good A/B fuel resistant epoxy to relocate the runners as required. Some intakes will respond to opening the runners to gasket size, if the openings extend up into the runners and provide a larger total opening, but in all cases, the intake runners must be in line with the gasket openings.

The next concern is installing/locating the intake such that the correctly dimensioned runner outlets are in line with the gaskets/head ports. This will be difficult if the intake is pulled to the front to compress the intake/front cover rubber O ring. That is why we suggest that the water crossover be cut loose from the intake portion. The water passageways can then be correctly sealed, and we can proceed to align the intake portion. Many race engines are accurately aligned with permanent pins in the heads and matching drilled openings in the intake. We can get very close to that accuracy in an easier manner. By cutting/aligning both the intake and heads to the same gasket, the bolt holes for all three will be in line, and can be used either for a visual indication of alignment, or we can go further. Most hardware stores sell nylon inserts that will fit into the ½" intake holes, but have a 3/8" ID. By installing/pressing one of these into each front hole of the intake section, the intake will be automatically aligned when the bolts are installed. It may be necessary to wallow out the holes through the nylon insert from side to side (engine left and right sides) to get the intake bolts started (due to the angles), but don’t open them front to rear.

Does this make a difference? It may not make a bit of difference in the power developed, but when we do such things as modify all aspects of an engine, bore, deck, cam, pistons, carb, intake, and so on, it is one of those basic preparations that will assure us that the intake/head fit will never degrade the power. and might even add a little! Again, at least align an intake gasket on both sides of whatever intake you are using (Victor, RPM, Performer, stock iron, stock AL, etc) and be prepared to be shocked with what you may see in runner outlet locations! Jim

[Jim Hand]

Jim M.
When we reference aligning an intake, we mean to do whatever is required to transfer maximum amount of air flow through the intake into the head. Some folks talk about "gasket matching", but that can be very misleading. In all cases, the intake gasket should be used as a reference when working both the heads and the intake.

The following may not be practical for engines with special intakes, matching numbers, special originality, or other such concerns. It is applicable to any attempt to obtain maximum performance from our engines.

Whether "ported" or not, the port openings on the heads should be cut to gasket size after the gasket openings are accurately marked onto the heads, and the openings should be blended into the ports for at least ½", and preferably farther. The same gaskets should then be secured to the intake and centered on the original Pontiac centering/locating holes - the holes that match the head holes that are made for the Fel Pro orange gasket hold-downs. You may be shocked at how badly all intake runners are aligned. It is not necessary to cut the intake outlets to gasket size in many cases, but it is important to move or realign them such that they are within the gaskets openings. Otherwise, the airflow coming through the intake will see a sudden obstacle of the gasket edge, or edge of the head port opening in the flow path. We use normal metal cutting tools, and good A/B fuel resistant epoxy to relocate the runners as required. Some intakes will respond to opening the runners to gasket size, if the openings extend up into the runners and provide a larger total opening, but in all cases, the intake runners must be in line with the gasket openings.

The next concern is installing/locating the intake such that the correctly dimensioned runner outlets are in line with the gaskets/head ports. This will be difficult if the intake is pulled to the front to compress the intake/front cover rubber O ring. That is why we suggest that the water crossover be cut loose from the intake portion. The water passageways can then be correctly sealed, and we can proceed to align the intake portion. Many race engines are accurately aligned with permanent pins in the heads and matching drilled openings in the intake. We can get very close to that accuracy in an easier manner. By cutting/aligning both the intake and heads to the same gasket, the bolt holes for all three will be in line, and can be used either for a visual indication of alignment, or we can go further. Most hardware stores sell nylon inserts that will fit into the ½" intake holes, but have a 3/8" ID. By installing/pressing one of these into each front hole of the intake section, the intake will be automatically aligned when the bolts are installed. It may be necessary to wallow out the holes through the nylon insert from side to side (engine left and right sides) to get the intake bolts started (due to the angles), but don’t open them front to rear.

Does this make a difference? It may not make a bit of difference in the power developed, but when we do such things as modify all aspects of an engine, bore, deck, cam, pistons, carb, intake, and so on, it is one of those basic preparations that will assure us that the intake/head fit will never degrade the power. and might even add a little! Again, at least align an intake gasket on both sides of whatever intake you are using (Victor, RPM, Performer, stock iron, stock AL, etc) and be prepared to be shocked with what you may see in runner outlet locations! Jim