Hey everyone,
I currently have some time and somewhat patience, so I think im going to take a swing at porting my TB with a dremel as some of you have done.

So before I get started, I would like those experienced at it to give me some tips and thoughts on the process and everything.

I want to port out the extra material, not port the entire thing. Anywyas, any help would be great guys. Maybe theres a writeup somewehre like the jeeb tb changeover?

die grinder and a micrometer

hand porting is a PITA with a dremel

wd-40 and lots of little sanding drums for the dremel. get varying grits too. the sanding drums will do a much faster job than a grinding stone type barrel...and dosent get clogged near as bad. just spray the inside with wd-40 ever now and then to clump the alum shavings together and it also helps to keep the drums free from clogs.

UPDATE: i just took off my TB and man! it-is-dirty-as-hell!?! Theres like back muck caked to the flap on both sides and the inside of the intake is horrible! Did someone say I can spray cleaner inside?? I dont wanna mess anything up, but yet i feel it needs help so to speak.

Teh WD-40 was to clump the aluminum shavings up helping you port it. I wouldnt spray it directly into the manifold IMO. Do a search for "seafoam". ;)

ok on the wd40, i took off the TB completely. but is there anything i can spray into the intake to clean it?

ALSO, when porting the TB, do you take off the center flap?

carb spray would worlk...thats just prolly carbon buildup...n' shit.

Originally posted by .bs0d
ok on the wd40, i took off the TB completely. but is there anything i can spray into the intake to clean it? ALSO, when porting the TB, do you take off the center flap?

You could take the butterfly out, but I dunno how hard it would be to put back in there? If you want it to be uniform, go for it! Seafoam cleans out carbon buildup. Google it. =)

Carbon buildup is gone! i went out and picked up some carb cleaner and it took care of that in no time. Right now i've just been polishing the TB with the dremel because I cant port it yet. the reason is because I cant find a micrometer. I figured autozone or O'Rilley would rent them, but they dont :( so maybe i can find one at walmart and take it back when im done ;)

yeah, carb cleaner is the SHIT imo. you think your TB looks bad, you ought to try taking out your entire intake mani assembly...its nasty as hell with all that carbon gunk from the EGR system. you must take out your throttle plate and shaft...and its not hard at all. hell, i can give you a walkthrough right here..

1. remove IAC motor and TPS sensor the bolts may be a bitch to get out but keep on them. these MUST be removed

2. when you lift your TPS sensor off youll see the throttle shaft. look closley and youll notice a circlip. this is somewhat of a PITA to get out. i suggest something with a point...work at it..youll get it out.
3. after that youll need to remove 2 torx screws (same size as those holding on the IAC and TPS). turn the throttle hammer over to WOT and push the plate out of the slot...towards the back of the TB (intake mani side). it will just slide right out.
4. next you need to disconnect the return spring. i suggest a screwdriver or nail..not your fingers. its wound up decently and can pop you in the hand.
5. now you can just grab the throttle hammer assembly and pull...the throttle shaft will just come right out, now your have a bare TB to work with.

you need the plate out because youll never get the TB properly ported...and youll damage the assembly because inevitably youll hit them with the grinder. plus its good to take it apart and give it a good cleaning...and hell for 79 cents a can for carb cleaner at walmart you can clean till your hearts content. youll DEFINATELY wanna take your TB off the intake mani assembly...youll have shavings out the ass and theres no sense in getting that down your intake runners. i dont suggest shooting any carb clener down into your intake mani. there is so much gunk buildup it would probably screw somethig up when it got sucked down into the combustion chamber. if you wish to clean your intake mani..i suggest complete removal...which is not THAT bad..just takes patience.

hope this helps and PM me if you have any more questions. good luck!

EDIT: and if you can get away with it (dont have emissions to deal with) i suggest removal of the EGR system...its pretty simple.