I recently acquired another Disco 2 project and am in the process of restoring it. I noticed on the intake manifold where the PVC would go the opening is blocked off by what I assume is epoxy (was trying to do the PVC mod by Best4x4). Short of removing the manifold and drilling it out, any other suggestions how I can remove this? I drilled into it a bit and removed some material but I'm afraid to drill too close to the IM and damage the thread.

 

The original fitting was plastic. Someone likely snapped it off and then tried to epoxy something in there. Really should probably just remove it to drill it out. You may find the threads are damaged anyway and have to put a different fitting in there. I have a couple extra manifolds I could ship you but the shipping is not going to be cheap unless you are close by.

 

You could replace just the front part of the a manifold, if required.
But I would pull the manifold, use a small drill bit to get through. Then slowly widen the hole with larger bits.

 

I got it out. I ended up removing the manifold, drilling a small hole in the epoxy, and stuck a flat blade screw driver in there. I wiggled it side to side to make a little slot and was able to turn and back out what's left of the old plastic PVC. I also removed the christmas-tree-looking plastic piece from the valve cover and it was completely caked in carbon. Hopefully this will fix some of the oil leaks on this disco.