Help with intake manifold corrosion

[felix1989]

Hi, I posted before asking for help cleaning the lower intake for my '99 Tahoe and the help I got was great. Problem is now that I have it clean I have noticed quite a bit of corrosion around the front coolant passages where the gasket goes. I can both see and feel the pits in the metal and have noticed that the bolt holes in the intake are somewhat corroded as well. This leads to my question, is the metal pitting too deep to just put the gasket on and hope for the best (I personally believe it is), what do I use to fill in the pits in the metal to level it up to the surrounding gasket surface, and would such a repair be reliable in the long run? While working I also came across some other questions that I need help answering, the bolt holes in the block for the intake bolts have some corrosion on them, what is the best way to clean them out, I am assuming a tap will be needed, what size and thread pitch do I need, and finally I picked up some ARP fasteners to replace the lower intake bolts, which are rusty as well, but the ARP package doesn't have any instructions on torque sequence or specs for the torque itself, and the website link for the instructions isn't working, the set I got were the stainless steel 12-point head bolts, though I didn't get the ARP lube for them, is there something else I can use in its place? I will attempt to add pictures of the corrosion on the manifold onto the post.

EDIT: As the images the board allows to be uploaded are quite small I well see if I can upload them elsewhere and link to them if anyone needs me to

 

[SunlitComet]

you really need to replace that manifold. you tap clean the holes in the head. should be 5/16-18. felpro makes the intake bolts with sealant already on them. Fel-Pro ES72224. make sure if you use the arp product that there is sealant on the thread because they screw into the coolant passages. torque sequence for manifold to heads is 26 in. lbs. on first pass, 107 in. lbs. on second and 11 ft lbs on third.

 

[felix1989]

That's what I was afraid of hearing, right now we cannot afford to replace the intake, or the fuel injection spider that is attached to it, but we really need the Tahoe back in working condition. I have heard multiple ways to fill the pits without replacing the manifold, but none seemed reasonable to try without more information. We really cannot afford to replace anything more on the engine and just need to get it running again, so is there any way to patch it up well enough that it will keep going?

 

[95escahoe]

Try a junkyard for a cleaner manifold?

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