Have a 502 MPI and just completed the third season on the crate engine. Had a slight oil leak I couldn't find so I removed the intake. The oil leak has nothing to do with my question.

Both sides on the rear of the intake over the water jackets appear to have some Bondo. When I installed it the first time it was flat and smooth, but now one side buldges out and has a crack. I chipped out the Bondo and a small amount of water came out; I'm guessing water got in behind it and froze over last winter. The opening behind it is pretty rough; so do I just clean the area, mix up some more Bondo and do some sand and smoothing?

I've repaired some intake manifolds that where corroded around the water jackets with a 2 part marine epoxy. Grind out the corrosion, apply the epoxy and grind to shape when dry. I used the intake gasket to get the proper opening shape. Bondo is porrous and absorbr moisture after awhile.

Look into MarineTex or JB Weld.

Sounds good I'll see if I can locate some epoxy. I realy don't know what it is, it just resembles bondo, light brown in color.

Thanks

I think the stuff I used was made by JB Weld. I got it at Lowes or Home Depot

I've used JB weld before and it worked well by applying a thin coat. I looking at around 1/8 to 1/4 inch deep in one area. Many thanks, I'll give it a try.

This was a marine epoxy. I was able to build it up in several places to at least 3/8" and let it dry before gringing it down. It was a 2 part system and was dark gray after mixing.

marine- tex works well, have used to form race intakes..very strong....Rob