Runner Removal
A MAPP/Oxy or Acetylene/Oxy torch is used for removing the runners. A small MAPP/Oxy torch kit is preferred as the torch tip and torch body is generally smaller, making them easier to work with. It takes about 40 minutes to remove all 8 runners. You'll need one cylinder of MAPP gas and 2-3 oxygen cylinders. The torch kit, MAPP gas cylinders and oxygen cylinders are available at Home Depot).

1. Use the torch to burn the epoxy off the retaining tabs at the tops of the runners. The epoxy will char and flake way from the heat and turbulence from the flame. Use a screwdriver between each pair of runners to confirm that the epoxy on the retaining tab of each two adjacent runners is removed. Pry just barely enough to see that the retaining tabs move relative to each other. DO NOT pry too much as the runners are fairly fragile.

2. Hold the intake in a vise in an orientation such that you can look inside the port of the runners that you'll be working on.

Note: The runners are removed in a sequence - 1&2, then 3&4, then 7&8, then 5&6, as numbered from either end of the manifold.

3. Heat runners 1 and 2 from the inside the port at the location corresponding to the bead of epoxy on the exterior face of the runner. When you're heating at the correct location, you'll see a plume of smoke as the epoxy is being cooked out. Work the flame slowly around the perimeter of the runner, thus cooking off the entire bead of epoxy. You'll need to move the torch tip from the primary to secondary port to do this. Keep the flame away from the edge of the runner as the runner is a low density casting and the edges are susceptible to deforming/melting if too much heat is applied too close to the edge of the runner. That said, only the edge of the runner is significantly prone to being melted by the torch - just keep the flame moving (slowly is fine) and don't let the cone of the flame stay in contact with the aluminum for too long.

4. While heating, use Channel-Lock pliers to work the runner back and forth to get it good and loose. Be very ginger with the pliers as the pliers can deform the runners. I recommend a set of channel locks where the gripping surfaces are parallel to each other rather than forming opposed V's. The ones shaped like V's will deform the runner.

5. Once runners 1 and 2 are sufficiently loose, you can pull them out. You'll have to inch each one out a little until they come out far enough for one to pop out and then the other. If needed, use a 1/4" ratchet extension or brass punch and a hammer to 'very lightly' tap the edge of the runner inside the port. Only tap the inside edge of the runner, NOT the interior wall of the runner. These runners are pretty brittle. If you need to tap on the runner to remove them, gently tap on the pair of runners, alternating back and forth between the two runners, until one pops free.

6. Repeat for 3&4, then 7&8 and then 5&6. Runners 3 and 6 can be rotated back and forth once runners 2 and 7, respectively, are removed. This makes 3 and 6 very easy to get out.
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