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The manifold is warped. I haven’t measured it, but it looks like around 1/8” or so. It’s at the front of the manifold. I don’t think it’s going to want to bend that much going back together. The middle and the back are flat. I have a belt sander but I can’t find any sanding belts that are the right size. If I can find the right size, it’s the wrong material. It’s going to take me for ever to make it flat with the belt I have now. I was wanting to get this finished this weekend. That’s not going to happen. I only had to drill and resize one hole. It was the very front. Thankfully it was the easier one to get to without having to get an extra long drill bit. We don’t have the corrosion out here compared to others. I can’t imagine having to deal with that. The O2 was a Bosch, I think. I made sure to keep the wires away from things.

I had a whistle from the intake tube on mine a while back. Drove me nuts. Near as I could tell, it was the sharp edge on the bung that the pipe feeding the idle air control goes into. I "reshaped" it a little with a big drill bit and it's been quiet since. Engine ran the same whether it was whistling or not, though.

So it's going back and forth between good and high? The mixture's actually supposed to bounce back and forth a little when it's in closed loop, that's how it controls the mixture with a narrowband oxygen sensor. Maybe the sensor's on its way out and it's responding very slowly? There is a test mode for the oxygen sensor, might be worth running that to see if the light's flashing like it should. Some codes don't trip the light, so I'd run those too on the off chance.