Been thinking of porting my plenum and runners for a while, and decided that it's time to do just that when I change the intake gasket (Since I have to remove them to do that anyway).

I am going to be using a Dremel tool, what bits and cutting/polishing wheels would you recommend me to use to get the job done properly?

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ZaphodB a.k.a Carl Andersson - zaphodb@faxancruisers.org
'89 Camaro IROC-Z 5.7L TPI - Mods under construction :-)
Custom ARAP Chip Under Development/180 t-stat, Edelbrock TES Headers,
SLP Airfoil, K&N Filters, Accel 8mm wires, Relocated MAT, AFPR @ 45 PSI

 

i would not use a dremel. you will be there for a long time. i tried a dremel a long time ago when i started my projects. i dont have the patience. it is slow going and the bits are small and short. so reaching inside is difficult.
i would use a die grinder with a carbide cutter, and some sand paper cones to smooth it out when your done. dont try using the stones...it doesnt work. and the little sand paper drums that come witha dremel just dont hold up. besides you will kill your dremel with the amount of time you will be using it.

if you have an air compressor, i would reccomend using a die grinder. and you get what you pay for so dont get the cheapest thing you can find. they suck and have no power. i got my cutter from snapon, it was like 40 bucks, but still looks like new. and i got my sandpapr tubes from www.grainger.com ( i think you could get the cutters there too) i also used a snapon extended reach grinder. it was more than i wanted to spend but it is the strongest die grinder i have ever used. and the long reach is great for everything you could use a die grinder for. hope this helps alittle

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87 z28 bowtie aluminum 420small block dry sump crower lt. wt. knife edged crank oliver lt wt rods brodix track 1's super ram intake slp 1 3/4 headers accel dfi art carr 700 r4 3.42 gears ssm sub frame/ladder bars.....other parts on the way ,soon to be finished!! couple more weeks!!!

http://people.ne.mediaone.net/gdm

 

While yes, it does take a while w/ a dremel, some of us don't have the luxury of an an air compressor to run a real grinder.
It took me the better part of a day to port my plenum, including opening and radiusing all the openings and some mild reshaping.
I used a basic high speed cutter (which yes is small, but works great anyway) for 90% of everything i did. Then i used a stone and a couple sanding rolls to smooth everything over.

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Ed Maher - Moderator @ The TPI & Carb Boards
92 Z28 Convertible - Quasar blue / Tan top
LB9 4L60 GU2 G80 - stock, soon to be sleeper
-=ICON Motorsports=-

- Definitely prototypes, high powered mutants of some kind. Too weird to live, too cool to die

 

It took me about 6 hrs to port mine, per Vaders tech article. I used a #196 high speed cutter, for the rough shaping/metal removal, several boxes of #408 60 grit sanding drums, and 2 boxes of #432 120 grit sanding drums. Now it looks nice and pretty inside . I also smoothed the runners (knocked down the step), on those I used the sanding drums, so I wouldn't go thru the runner. It takes time but if you're patient it can be done with the dremel

 

I used a wizard[ same as dremel] well kinda. Anyways I bought a couple of carbide burs [local hardware store] and several packages 40-60-120 grit sanding wheels. Also used a flexable shaft. You can reach down in the intake alot easier with the dremel and not near as much noise. I kept the bur soaked with atf. It makes geting the aluminum off so much easier. And I only used two of those burs to do intake, plenum, and heads.

 

wd-40 works well too

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87 z28 bowtie aluminum 420small block dry sump crower lt. wt. knife edged crank oliver lt wt rods brodix track 1's super ram intake slp 1 3/4 headers accel dfi art carr 700 r4 3.42 gears ssm sub frame/ladder bars.....other parts on the way ,soon to be finished!! couple more weeks!!!

http://people.ne.mediaone.net/gdm

 

I used a Dremel to knock down the EGR walls behind the TB. That was an easy job to do with a "soft metal" cutting bit. Took about an hour. This was my first time porting, as well. I don't have tons of money lying around, and the Dremel was just sitting around. It'll work fine.

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88 Trans Am 305 Auto Red/Silver, MSD coil,wires, ported plenum, gutted airbox, TB bypass, comp cams 08-408-8, everything else stock

 

I've used both methods and yes they both will work fine. The dremel just takes longer, but that can be a good thing. Much harder to screw things up when you are using a small tool and going slow. (This approach might work for other endeavors.) As mentioned above, get a soft metal bit to do the removal work and smooth it out with the sanding rolls.