Windstar Conversion Kit – How To Modify A Salvage Yard Intake Tools Needed • • • Degreaser and compatible elbow grease 5/8” Spade Bit Wood hand saw or saw-zaw Modifying the Intake Now would be a good time to clean the intake. It makes working with the intake, performing the modifications, much cleaner. A pressure washer works well to remove the thick grime often seen on the intakes. Letting a good degreaser soak on the grease will help as well. The first step is to cut off the top IAC port from the Windstar intake manifold. You want to cut it off approximately flush with the top of the 3/8” barb right behind that IAC port. See picture. This can be done with a wood hand saw or electric saw-zaw with wood blade. If using the power tool be careful to make the cut straight and not let the blade run away in the material. You can then use a file or bench grinder to smooth out the top section. (see the picture on page 4) After Cutting off Top IAC Port 1 Next you need to drill a 5/8” hole about 1” behind the bottom of the throttle body mount. Use a spade bit attached to an electric drill. Place something (wood, rubber, doesn’t matter much) inside the throttle body opening while drilling the hole. This will prevent you from stabbing the intake when the hole finally breaks through. After the hole is drilled take the 5/8” brass elbow and using a pliers, carefully snap it into the hole. The elbow should be a snug fit and should support itself in the hole. Snap brass elbow into drilled hole 2 At this time you can also use the 5/8” spade bit to drill the vacuum line passage ways between the ribs on the underside of the intake. See the pictures below for the location of the 4 slots to be created. Cut passage ways into intake as shown. 3 Next up you need to set the JB Weld on the IAC block off port. With the intake right side up apply a moderate later of the epoxy on the cut portion of the IAC port. Place the provided IAC block off plate onto the glued surface. Let dry for 12 hours. - Epoxy on IAC cover plate and the finished result. 4 After the epoxy is dry, flip the intake over. Fill up the IAC port, from the inside of the throttle body opening, with JB Weld. Also seal the brass elbow to the intake by applying a generous circle of JB Weld around the fitting. Fill inside IAC hole and around brass elbow with epoxy. 5 You are done! Perform a final clean on the intake to remove any plastic filings and dirt. A wipe down with of STP Sun of a Gun or Mothers Back to Black will give the intake a like-new black shine. Products recommended to make your intake look like new! 6