I am having my engines with the Whipple 3300 on them rebuilt. We had to get new intake manifolds due to some corrosion on the original intakes. Here is a pic of the new intake, and the whipple gasket. Why didn't they make the water bypass port match up with the gasket?

We were thinking about porting that but it might be too thin in that area. Not sure yet. Thoughts?

Also, there is no finish on this part besides the paint. I am suprised that they don't clear anodize the part prior to painting. Naked alluminum will eventually corrode without protection (like my last intakes did). Think I could anodize the part with the paint on it or maybe at least a chem film (irridite).

You may want to send your question/pictures to Dart Heads ...They claim to be proficient with their coatings.

Are intake manifolds not normally plated at all?

The Merc aluminum ones have bronze cooling passage liners and are painted on all exterior surfaces.

I wouldnt worry about the passages lining up perfectly, Still plenty of flow thru the opening

Yes.....but look at my last manifold. This is 5 years old. There was no protection on the bare aluminum!!!

I know u can get them coated after ....i think Dart does this as well as other companys..its only like 200 bucks or so ?!

Is that a Whipple manifold? You may want to check with Canfield or one of the other head manufacturers. I know they hard anodize their marine heads, but you still need to flush religiously. Since that one lasted 5 years I suspect you do a good job of flushing, I had one puke in a year of brackish water. BTW, there should be Merc Perfect Seal used around all those water ports when the gasket is installed, it will help keep that from happening also.