It never ends, does it? When I returned from shopping this morning (in TP, carby sedan), I heard a hissing sound coming from under the bonnet. Opened the bonnet and it smelt hot but coolant level was ok. Felt around for a bit and could feel steam coming from under the back of the air cleaner on the drivers side.

After it cooled down, I took off the air cleaner to investigate.

This is what I found. One of the pipes on the manifold, where a hose connects to it, has corroded away. (centre of the 1st pic.). The other end of the hose comes from the water pump (small one, just top left of centre in the second pic.)

So, how do i fix this other than a complete new manfold?

I'm thinking of two possibilities.
(1) drill out and clean up the hole and try to press fit a piece of brass tubing into it so that I can re-fit the hose. Not sure whether this will hold for long.
or
(2) drill and tap the hole and close it off with a bolt and fibre washer, then connect the hose using a tee piece to the similar hose next to it. Can't see why this would not work.

Your comments and any other suggestions for fixing it would be appreciated.

It is lucky I've only been doing short 2 to 5km trips with it. I was about to go for an 8 hour trip and would have cooked it.

apply axle grease to the drill and taps to stop fillings entering the cooling system

there is eneough meat to drill out and retap it

drill out the fitting
retap
and put in a new fitting

or a s/h manifold

at the water pump buy a half pump and fit that

I didn't realise the fittings were threaded. Where would you get them from?

repco

if not ... tap the size of the hole to suit a plumbers thread or gas thread

that includes compressor hose fittings for a size

first genners rock

Thanks, magna buff, that's the sort of info I needed.