I installed a blue thunder intake on my bird and when I installed the  thermostat housing with a gasket it leaked like a waterfall. I took it off and filed it trying to smooth it . I also checked the intake and filed it too. Re-installed the thing and waterfall city. Took it off and installed the housing with silicone sealant and no leak. I would like to use a gasket but dont think I can. Anybody have/had this issue ? Any suggestions?

55Birdman  Hickory NC

Not with a Blue Thunder but had the same type of problem with the stock manifold and thermostat housing. I used two gaskets plus some Permatex Ultra copper RTV (101BR) on all surfaces. On all aluminum manifolds I ever used, I put studs in the intake - this stops wear and tear on the threads in the intake and provides a smooth installation of the thermostat housing.

54 Victoria 312;  48 Ford Conv 302, 56 Bird 312
Forever Ford
Midland Park, NJ

Earl,Mine leaked when I installed a stock cast iron manifold.Filed and sanded 3 times before I gave in and put on a new housing.Fixed it!Keep an eye on yours just because its not leaking now doesn't mean it won't after a few hot cycles.Hope it works for you!

  

Mark I guess thats what I am trying to not do . Get a new housing. I guess the sealant is thicker than the gasket and thus seals better. The blue thunder had a high spot on it about 8 o'clock position.I filed it down but still leaked.  I think I will put studs in the intake and I will try 2 gaskets and sealant tomorrow . The sealant is more flexible and fills the void better I suppose.  I just never had this pop up before. Just wanting to make sure I am thinking properly. But, this doesn't necessarily mean I am thinking at all.  

55Birdman  Hickory NC

This won't fix your problem, but I think I heard there has been a few problems with quality control on some Blue Thunder Intakes. Apparently, recently they were behind in delivery, maybe that has led to haste making waste? For anyone considering purchasing an aluminum intake, John Mummert in CA is supposedly having a re designed 4 Bbl intake marketed soon. It is supposed to be a more street friendly version. This is just for info, I'm not trying to sell anything..

Paul

Earl:

Is it possible that the thermostat housing has been filed/sanded too many times, the recess for the thermostat is no longer deep enough?  If the  'stat is too thick for the recess, it would prevent the housing from sealing against the gasket.

John in Selma, IN

John - "The Hoosier Hurricane"

I took the housing to a machine shop this AM and it is shot. It has a low spot that caused the leak. I tried 2 gaskets and it has a slow drip,so I added some sealer and its doing ok now. I guess I will feel better if I get a new one. Anybody got a housing?  

55Birdman  Hickory NC

Earl,

      I have new ones in aluminum, with a stainless bypass for your 'Bird. Send me a PM if you want one.

       

Frank/Rebop

Bristol, In ( by Elkhart) 

Not trying to sell anything here, but Frank's housing is a really nice piece and looks much better with an aluminum manifold than the old cast iron one.










Johnson Rod



Southern California

I would like to have one but, I am retired and my wife just lost her job and "dead presidents" are scarce here for now. I will have to figure out how to pay for it.

55Birdman  Hickory NC