I'm sure someone, somewhere broke their manifold. How many car from the
50s, 60s, or 70s made 260 hp from 4.6L? Technology allows us to move forward. If we did it like you so badly want to, we might still be driving an old 302 making less power. Grasp technology...don't shun it.You make it sound like it WILL break if it's plastic. Plastic manifolds don't necessarily have to break. Plastic manifolds molded incorrectly may break, but that's why Ford offered an extended warranty on that part. BTW...there are plenty of cars with plastic manifolds on them running fine...the LS1s in the Corvette, Camaro, and Firebird; I think some of Ford's FWD V6s; the 2.0L I4 that's in the Contour, Focus, etc; the Dodge Neon, and many, many others. The 4.6 water passage was an accident (we all make them...admit it). Learn and move on. BTW...the '99+ cars didn't have this problem, and in '02 Ford really did it right and made the crossover from aluminum. They left the rest of the intake plastic. Why? Cheaper, lighter, and cooler all make for better performance (the first is the performance of a dollar :-) ).
That would truly be cool, and I'm sure you'll see something in the not too distant future. Not all plastic has to melt at high temperatures like a model kit melting down on the stove. You may actually see an entire engine made of plastic and ceramic composites in your lifetime (assuming you're not
70+ yrs old). Think of how light it would be. Ceramics are very durable. Plastics can be made to be. Very cool...