Well, the previous owner had someone do some mild porting on the intake manifold, so he says, I havent taken it off yet to verify, but I got a nice new dremel set and am eager to port the fuk out of it. I should be able to do a good enough job with one of those flex pen extensions and a shit load of grinding stones, right? and a wire bit to polish it up? I have never done any porting before, but all your doing is removing metal, and i have seen the machinest at some local shops, and they dont look to brite, so i figure i can do it myself and learn a little in the process... anyone have any tips? how much should i port it n' shit?

I say go with a basic gasket match on it. Open the runners up to the size of the gaskets and I also took a little bit of material off the top of the fuel injector boss where it pokes down in to the runner but not too much. With your boost levels you may as well make the runners as big as possible to get as much air in that beast as possible. Make the runners smooth when you are done porting but a shiny polish isn't needed. Good luck. Get some flat stones not just the cone shaped ones. I also had luck using the little round sandpapers too.




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MSD DIS-2 Ignition System
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Ported Intake Manifold
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hey brad, when u do it, can you write up a small how to??

im sure many people would appreciate it, including me.

tia

I'll give you a simple write up write now. Attach flex extention to dremel, attach stone, work the fuck out of it for about 8+hrs straight minumum reaching all the hard to reach corners with different shape stones. Look at the huge pile of aluminum you have created. Get a fine stone to smooth the interior glassy smooth. I sure as hell didn't anything to go by. I started slow and an hr later I was flinging the flex extension throughout the manifold like a Jigalo on a $1000 job. I didn't do anything to the injector bosses except the smooth the surfaces. Everything else I bored pretty good. I then took it to a professional and had them port match it to the head and TB. I dont know what porting alone did but with the 55mm it was a damn good mod. Engine revved like I put a aluminum flywheel in it and that was just blipping the throttle before I even put the car in gear.

knowing my luck i would mess it up and have to buy an aftermarket one

there's no such demon, they're working on a venom intake, but its expensive and will require a lot of mods to make it work... same with ray's intake he custom fabricates, and neither will hold an idle, if you fxck it up, which i doubt you will, then just pull one from a junkyard and start again... i guess i'll start on mine as soon i as get it back off... damn, i just got the car running again and here i go...

I am just adding another note it doesnt have to be a super shiny smooth finish air tends to flow better with a slight amount of "dimples" I will see if I can get some pics up of the 99 cobra intake mani I did a few months ago. I have also done a mild port job on mine. I mainly did mine to clean up any sort of casting flash that I had. With mine I started out with it on a CNC mill and made the ports a uniform shape so I could get a consistant air flow. Then I used an air grinder and an arangement of different stones from very rough to smooth. Also look into its the cone shaped sand paper. I dont know the technical name off the top of my head but they flex somewhat so I could get areas that I had a hard time getting with a stone. Also I cant emphisize make sure to clean it out good very good. Hope that helps somewhat. I will try to get the pics of the job that I worked on.

The intake ports on the head should be left ruff to encourage turbulance inside the chamber but ruff (dimpled?) interiored intake manifold can only create friction and restriction for the airs path. Extrude honing and all the new composite plasitc intake manifolds are smooth. When I say glassy smooth I exaggerated a bit. More like smooth when running your fingers across it.

I've done it.. along with the plenum inlet, runners and all. It took me about an hour and a half to do it with a compressor. Even polished the outer part of the plenum... of course that didn't last.. it's been years and it went dull.

Oh.. I went as big as the gasket which is port matched to the intake on my head.

THis is kinda off the topic, but can i use the dremel and stones and stuff just to polish other stuff that has started to get rusty in my engine compartment??

thanks for the insight, stan, eric and raizin.

yes but its very difficult. I played around with some attachments attempting to polish somethings. Its hard to polish sh*t evenly with it. I probably didn't use the right attachments either so who knows. I'm sure with the right attachment you can polish with it. There hasn't been anything else the dremel hasnt been able to do (cut through steel, drill, whatever. if I need it done the dremel has an attachment that can be bought)

It might not polish it evenly but it would get most of the rust off right??

fuck, i forget what they're called but yeah, they do have a thick wire extension piece that will polish metals up really nicely, i did the intake side of the turbo and it looks 10x better.

go for it dood, and watch what you say about those machinists. i'm sure one of them hadda mullet, just like me!!!!!