Boo, phenolic is heat and gas resistent, and can be worked with wood tools, like routers,hole saws. Roughed the piece into shape on the table saw,dressed the edges with a router.
I opened up the top of a stock 261 intake by using a hole saw in the drill press, then attacked it with a grinder to dress it up.Made and oval hole to match the carb,In my case, the carb is a Holley 2300 two barrel.
I had to do a little welding as the grinding punched into the exhaust heated cavity in the intake manifold.I used a MIG welder with steel wire,welded up a few small holes in the cast intake ,no problem.Brazing will also work or if you're a gambler, JB epoxy weld may work.
I then machined a piece of 1 inch phenolic as a carb flange, drilled 4 holes ,tapped the intake so I could bolt on the flange, made a gasket,etc.
If you're interested,email me at alltruckedup@earthlink.net, I can fix ya up with a piece of phenolic for free,just for you buddy,lol.
