Clearance issues...

[2.8-350TBI]

So, I "mocked up" my 3.4/3500 at the shop today, and I ran into this little issue.
The lower intake manifold doesnt clear the timing cover tab, and I really dont know wether that tab can be ground/machined off or what.

I tried doing it with my 3400 top end and I had the same result.

Any 3.4/3500 (forcedfirebird) guys care to chime in?

Thanks in advance

Here are a few pix:

[CNCguy]

The easiest is to cut that area off of the cover using a bandsaw or milling machine. A hacksaw or grinder will work but is slow.

[86FieroSEv6]

Just make sure to evaluate whether or not you can lose that bolt position and maintain support.

[ForcedFirebird]

Whack that sucker off!

As CNCGuy mentioned, you can use various methods, but before I bought the band saw, using an angle grinder with a cut of wheel seemed to work fine. That tab is unused in a hybrid anyways, just make sure you don't slice into the gasket sealing surface.

[CNCguy]

If you are careful and have one at your disposal you can use a table saw with a carbide tipped blade. It kicks ass and will cut faster than a bandsaw. We have a 14" chop saw with a carbide tipped wood blade from Lowes that we use to cut aluminum, brass, plastic and wood. You can fly through a 4 x 4 bar of aluminum is a couple of seconds. Just put a little WD40 occasionally to keep the aluminum from galling to the carbide tips.

[2.8-350TBI]

If you are careful and have one at your disposal you can use a table saw with a carbide tipped blade. It kicks ass and will cut faster than a bandsaw. We have a 14" chop saw with a carbide tipped wood blade from Lowes that we use to cut aluminum, brass, plastic and wood. You can fly through a 4 x 4 bar of aluminum is a couple of seconds. Just put a little WD40 occasionally to keep the aluminum from galling to the carbide tips.

Holy crap 0_o

I wouldnt trust myself with that, unless it was the table mounted kind that hinges downward (what are they called?)

Do you think I can do it with a scroll saw?

EDIT: Is there enough meat under the tab so that there wont be a gaping hole into the timing cover?

[pocket-rocket]

Holy crap 0_o

I wouldnt trust myself with that, unless it was the table mounted kind that hinges downward (what are they called?)

Do you think I can do it with a scroll saw?

EDIT: Is there enough meat under the tab so that there wont be a gaping hole into the timing cover?

That is a chop saw. There should be enough meat there. John chopped his off a long time ago for the 'Bird.

[2.8-350TBI]

That is a chop saw. There should be enough meat there. John chopped his off a long time ago for the 'Bird.

Okay thanks pocket-rocket.
I will try to find someone with a chop saw. If not it will be the table saw.
I dont know why I said I wouldnt trust myself with a table saw, if I cut aluminum on a table saw all the time, but it is thin sheets of aluminum I use to create r/c chassies.
My fingers come within a half inch of the blade sometimes but I guess im scared since I havent done a timing cover before lol.

[Driver_10]

Your entirely too worried. Heres my 3400. Used a saws-all and got-r-done. Fits nice and flush.

[pocket-rocket]

If you are afraid of it grabbing the cover and puling your fingers in (which would be a good concern, lol) you could always find someone with a bandsaw, like mentioned already. It really would be a safer bet for something like this, as would the saws-all like driver10 mentioned. Then just clean the area up with a die grinder.

[geoffinbc]

It can go. All that chunk is there for is to pry the cover off during gasket changes and to support the clamping tool used during water pump changes. But the cover comes off just as easy with a rubber mallet and no one ever uses the clamping tool when they change the pump.

[ForcedFirebird]

If you are careful and have one at your disposal you can use a table saw with a carbide tipped blade. It kicks ass and will cut faster than a bandsaw. We have a 14" chop saw with a carbide tipped wood blade from Lowes that we use to cut aluminum, brass, plastic and wood. You can fly through a 4 x 4 bar of aluminum is a couple of seconds. Just put a little WD40 occasionally to keep the aluminum from galling to the carbide tips.

Yup. i have a chop-saw in the shop, but don't like cuting pipe with it because the 180* bends get nicked when the blade is at full drop. It's a 10 incher, and will buzz through 2"x2" solid aluminum in seconds (pipe also, but read above)...

I don;t know that I would trust a table saw, not only is it akward, it would be tough not to hack the other 2 tabs next to it. Going with what Driver said, you could use a sawz-all or even a jig saw if you can't locate a band saw.

Jon, I have hacked so many of them now since I did mine, actually lost count haha.

[Superdave]

I used a hack saw, then a die grinder to clean up the edges. Fits like factory.