I received an email from Tony at LCE. He had this to say about the surfaces: "We actually get these straight from the foundry quite rough.
Offy finish is horrible, so we do it here."
This means they resurface the intake at their shop, I'm assuming this applies to the bottom water plate as well.
I explained the methods I had used to seal it, and he was surprised. He recommended this: "If a gasket is giving you this much trouble, I would get a tube of Hi Temp Copper RTV Silicone
Gasket Maker and use that with no gasket. I've used Ultra Grey with no issue, but Copper is called for coolant."
I think if the stop leak doesn't work, I'll try this. Coupled with the thread sealant you recommended.
It appears to be still leaking currently, but they say it takes up to 200 miles to seal. If it doesn't seal I'll do the aforementioned.
Crazy thought, what if I made a CNC machined intake for this truck? Two halves, completely custom. Only ports that I need. Ideas...
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I'm a fan of trying new things in the name of learning. I bet you'd learn a lot in the process. It would probably be more work than just welding the thing together, but sometimes more work isn't the point.
