Since I was going to have to order the darn gasket and wait a week I decided to chase down some gasket material and make my own. Which wasn’t all that difficult really. Just take the intake manifold and use it as a template to cut a new gasket. $6 and 15 minutes later I have a new gasket. (You can only buy the gasket material in bulk).

So, as I’m scraping the old gasket off I make a discovery. I found the reason that the gasket blew. And darn it, if it wasn’t my own fault. If you look at the close up below of one of the bolts studs you will see an odd discolored ring. That’s a washer under the old gasket.

From Wally the Superbeetle

Yep, seems I put the washers on the studs when I took the motor apart so I wouldn’t lose them. And then forgot they were there. So, no matter how tight I cranked down the bolts, there was always going to be a gap. Grrrrrr. My own mistake. Oh well, live and learn. It’s fixed and running much much better now. Idles nicely and has decent power again.

Anyone need a bunch of gasket material? I’ve got lots left over. 🙂