I want to gasket match my upper plenum and middle .This may sound like a stupid question . But , what does this involve ? Is it just matching the gaskets up and cutting off excess that does not need to be there ? I would also like to take my intake manifold off and port it ? Or atleast grind down chunks of metal sticking up in the ( gosh , cant think of what the hell they are called ) you know the holes in the intake manifold going into the heads ) I really dont know if I can (Port -as in remove metal) but atleast I should be able to move the chunks of metal blocking flow. that dont need to be there .Thanx guys .

 

i did port my upper , lower plenum and intake manifold...

i used a dremel with 120 grit sanding discs and sometimes 80 grit in places where things are rough...

and also a couple of wirebrushes to smooth the surfaces....

i got the flexshaft for the dremel too (from camaro_hunter_d) that helps a lot in reaching out of reach places...

dont expect to find chunks of unwanted metal inside... ull hardly find casting defects on the inside ...

dont use 80 grit unless u know what u are doing cos the aluminium manifolds get ground off very easy even with the 120 grit ...

i can bet though ull have to clean the insides with carb cleaner or something to clean it totally before even starting to sand

matching gaskets is simple... u open a manifold and see on the inside till what point on the wall is the black mark go to...till that black mark u sand (be very careful though)
u repeat the above for all the holes...

 

Awesome man ! What speed did you set your dremel on ?

 

I pretty much did his lower manifold. I used (Speed)4? I think. Depends on the sanding drums. We both bought an *** load of 1" long drums for a quarter a piece, but they kept flying apart, so they had to be cut in half to be used right. Anyway I pretty much bored out where the injectors go and really opened that part up. He did the intermediate and upper. When you do your intermediate (and all the others for that matter) you want to sand the corners in the passages untill the drum is flush. You are basically expanding the 1/4 corner to 1/2 and smoothing the lefft over "hump" out untill its kinda even.

I think by doing that you get a extra 1"-1.5" of extra flow area per port. Which means alot.

 

Thanx as always . Hopefully by this time next year I will have some of your headers and y-pipe to get this air flowing out better !

 

Just FYI your gonna need a good 40 Yes 40 of those drum sanding things. Try to find a supply store that sells the 1 inch things for like a quarter a pop. That way you only need 20. 20 by four is 5 bucks! Alot better then 6 for 3-4 bucks like dremel has them packaged. Hell at that price your gonna spend 36+ bucks on the sanding drums!.

 

CHD,

Couldn't you use one of the grinding stones then use the snading drum to dress it up? Just a thought.

 

The Dremel grinding stones are made for harder metal then aluminum. The one I have just gets caked with aluminum in like 2 mimutes...

 

yep ...DONT USE GRINDING STONES THAT COME IN ONE PIECE... thats okay for the heads but not for the manifolds...

teh thing is u can get 1/4" drums about 40 pieces
and the smaller one ... i donno what size is that thats allso a dremel fitting ... thats easier to use for the corners...

yep they eat metal fast so u gotta watch out for that...

and u also need a gasket kit ...if u buy felpro from autozone for like 20 bucks u get valve cover gaskets with it too..

setting 4 i think is like 20,000 RPM.. but ull have to get that like faster first and then slower as to not make mistakes... took me like 3 hrs for one manifold...

drum sanding things ... dremel is very expensive and ull go thru a lot of those ... so find a cheaper alternative like in a local harware store.....120 grit

 

I have never used a sanding drum or stone for my porting

just use a high speed cutting bit
I think 115 or 135

can get things nice and smooth off just one of those so far

 

hey rx7 ur intake is steel ... wherein the cuttin disc might work but in alum. ur gonna eat the metal away soon with those