2.25 Petrol Intake Manifold Crack

[Whoneedssleep]

Hello All,
I cracked the mounting ears on the intake manifold of my '79 S3 2.25 petrol. I'd done my homework—read articles, watched videos—and thought I was in the clear. Unfortunately, I wasn't.

NOTE: I had a bad head gasket, so the intake and exhaust manifolds were removed. I purchased a new exhaust manifold but kept the original intake.

After torquing the exhaust/intake manifold bolts to the head, I began slowly tightening the intake and exhaust manifolds together. I used a stubby wrench and applied very little pressure, but still—POP. The intake cracked right where it attaches to the block. Clearly, I did something wrong - when it broke, I still had a gap between the intake/exhaust manifolds. I've attached images for reference.

A couple of questions:

• Can this intake be repaired? Even if cast aluminum can be repaired, I fear a perfectly flat surface might be hard to achieve.
• I've only seen used replacements online (eBay, etc.) going for just under $300. Any other sources or suggestions?
• After I get new parts, anyone have a better "idiot proof" way of assembling these components?

Thanks in advance for any help!
- Mitch

[jimrr]

I'd suggest clamping the manifolds to a flat plate, then tighten the manifolds together (with the gasket) but tap them together with a rubber mallett and loosen/tighten the clamps alternatly and put some light grease on there to help them slide as you tighten them together..... yes, you can have someone weld the ears back on there and save a few bucks, it'll work. you might also want some hi temp copper coat or similar on those bolts as well?