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Old 12-17-2004, 12:44 AM   #26
ITLRUN
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Those of you that have completed this mod.... what differences did you notice?

It looks like a lot of work.... and I'm lazy lol
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Old 12-17-2004, 12:49 AM   #27
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Quote:
Originally posted by Slicksaleen
ALDI RULES! Keep the pics coming, very nice writeup so far
Thats what helps pay for the mods on this car
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Old 12-17-2004, 01:06 AM   #28
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Well I am done for the night. Kids went to bed so I can't make anymore noise. I am at the 'rough' stage right now. I have passed the metal grinding bits down each runner and have removed all the flashing from the top and bottom. Tomorrow I will wash it off and 'feel' for any high spots or roughness. After taking care of that then I will start with the grinding wheels and start shaping and smoothing. Hopefully by tomorrow night I will have a fairly polished lower intake. Then I will work on the lid.

Here is how it sits in rough form:



Picture of one of the runners. Notice I still need to find a way to get a little lower in the runner? I have the Dremmel Flex Shaft, but it is still a little short. I may try and hand smooth out that area. I don't think I will we doing any enlarging of that area.





Here is that dang mystery oval port. I cleaned up some flashing, but kind of at a loss for any further enlarging of the opening. All the round horns actually look really good so I just cleaned them up a bit.



I think I am going to get a new PCV valve to. My intake looks a lot oilier then all the other ones I have seen Maybe because it isn't a daily driver
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294.2 RWHP 314.0 RWTQ 1/25/05 SAE.
12.61@108MPH 04/16/06
Magnaflow Magnapaks,MRT Catted H pipe SCT Xcalibrator tune,Ported/Polished lower intake with PHP spacer,S&B 8" Powerstack filter on Lowes CAI, MGW Shifter, Strange 31 spline axles, FRPP 31 spline diff with carbon fiber clutches, FRPP 4.10 gears,17x9 and 17x10.5 Black FR500 rims, BFG drag radials
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Old 12-17-2004, 01:15 AM   #29
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Good luck with the project! Keep us updated. :THUMBSUP:
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Old 12-17-2004, 11:15 AM   #30
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Last edited by Nazman; 10-16-2007 at 07:06 PM.
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Old 12-17-2004, 12:16 PM   #31
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Thanks NAZ !!!! :HOPPY: :THUMBSUP: Those help a lot.

I was able to get all the flaring into the 6 down runners done. I am a little worried about totally removing the fuel rail bosses inside. I dont want to reveal a bolt hole all of a sudden. I will work more on the flutes in the bottom, but I don't think I can get it as flared as yours strictly thru the casting ports.

Round 2 '*ding*'
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Build Date 11/04/03
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12.61@108MPH 04/16/06
Magnaflow Magnapaks,MRT Catted H pipe SCT Xcalibrator tune,Ported/Polished lower intake with PHP spacer,S&B 8" Powerstack filter on Lowes CAI, MGW Shifter, Strange 31 spline axles, FRPP 31 spline diff with carbon fiber clutches, FRPP 4.10 gears,17x9 and 17x10.5 Black FR500 rims, BFG drag radials
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Old 12-17-2004, 04:30 PM   #32
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[QUOTE]Originally posted by Comp Orange 04
[B]Thanks NAZ !!!! :HOPPY: :THUMBSUP: Those help a lot.

...

Last edited by Nazman; 10-16-2007 at 07:06 PM.
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Old 12-17-2004, 05:20 PM   #33
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I don't wish to hi-jack this thread either, you're doing a great job, but it just seems a lot of work, together with the fact that not all the inside surfaces get polished.

I just wanted to say that I just got off the phone with a Rick Miller of Extrude Hone down in Irwin PA and I was thinking about volunteering my upper intake manifold to him for tooling (I would get a substantial discount of course). All told, it would take about 3 weeks (from Jan 3, 2005), and once done, Rick would report the flow percentage increase. Once the tooling is complete, the process would only take days for the other intakes sent in to him. I'm very interested in doing this, but I don't have a garage, and I would have to pull the intake out in the cold, plus figure a way to cover the exposed engine ports (I only have a car cover right now). Time to crap or get off the pot I guess, **** I hate winter! I'll let everyone know very soon what I intend to do.

The good news is that I told him how I was a member of this site and if he'd be interested in giving us a group purchase price, and he said YES! Final group price will be determined after tooling and the first intake is completed, but he feels it should be around $450.
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Old 12-17-2004, 05:39 PM   #34
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Old 12-17-2004, 06:10 PM   #35
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Well here are some port shots. I am pretty much at my limit on the flaring side due to the access port size. I have started smoothing back on some. Here is one with just the flare done.



Here is the 'D' port, still need to get rid of the ridge on the left side.



Here is one that is almost complete except for smoothing



And this one is done except for smoothing.



Not too much time has been spent so far. Always remember your safety glasses and gloves. I cannot believe how many metal fragments are lying on my table. And that is probably only half since the rest are in the intake still!
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Magnaflow Magnapaks,MRT Catted H pipe SCT Xcalibrator tune,Ported/Polished lower intake with PHP spacer,S&B 8" Powerstack filter on Lowes CAI, MGW Shifter, Strange 31 spline axles, FRPP 31 spline diff with carbon fiber clutches, FRPP 4.10 gears,17x9 and 17x10.5 Black FR500 rims, BFG drag radials

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Old 12-17-2004, 09:16 PM   #36
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Old 12-20-2004, 10:32 AM   #37
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I am having some problems finding a 1" flap wheel.... Any suggestions? I went to Wal Mart, Lowes and Menards.
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Build Date 11/04/03
277.1 RWHP 301.2 RWTQ 1/28/04 SAE Stock
294.2 RWHP 314.0 RWTQ 1/25/05 SAE.
12.61@108MPH 04/16/06
Magnaflow Magnapaks,MRT Catted H pipe SCT Xcalibrator tune,Ported/Polished lower intake with PHP spacer,S&B 8" Powerstack filter on Lowes CAI, MGW Shifter, Strange 31 spline axles, FRPP 31 spline diff with carbon fiber clutches, FRPP 4.10 gears,17x9 and 17x10.5 Black FR500 rims, BFG drag radials
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Old 12-21-2004, 03:37 AM   #38
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Ok, found a 1" flap wheel at NAPA, back to work..........
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Build Date 11/04/03
277.1 RWHP 301.2 RWTQ 1/28/04 SAE Stock
294.2 RWHP 314.0 RWTQ 1/25/05 SAE.
12.61@108MPH 04/16/06
Magnaflow Magnapaks,MRT Catted H pipe SCT Xcalibrator tune,Ported/Polished lower intake with PHP spacer,S&B 8" Powerstack filter on Lowes CAI, MGW Shifter, Strange 31 spline axles, FRPP 31 spline diff with carbon fiber clutches, FRPP 4.10 gears,17x9 and 17x10.5 Black FR500 rims, BFG drag radials
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Old 12-21-2004, 06:21 AM   #39
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Cutting open the bottom

To add a bit more to the porting information sharing. Here are
some pictures of those velocity stacks after the bottom is removed. This is where most of the casting flash is left behind on the sand casted intake.

These intakes are made from several Half's you might call them. The seams all come together at the bottom, on the inside of the intake. This leaves much to be desired in the flow of air to those runners.

The surface finish is the shape or roughness of the sand used to make the casting with.

An injection molded plastic intake would have been the best way to go. But its to costly for Ford to produce for such low manufacturing volume.

They have finally made that leap with the 05 GT.

I work on "Camry" intake molds every night at work and study the flow mechanics of it. While its not a hod rod car part, its quite a nice piece of work. All the runners are like an Extrude hone finish. And there are absolutely no obstructions in the air flow path like our Mach-1's.

As Nazman said, its not the velocity of the incoming air charge. Its the volume of air the intake is being choked out of.

By the way, Pauls high performance does both. Cuts open the intake, Extrude hones and then ports the rest by hand. $1,250 plus your core. Good luck with the grinding. And where your safety glasses at all times.
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Old 12-21-2004, 07:20 AM   #40
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So how do you put the intake back together after you cut the bottom off? Seems like a fairly hard aluminium weld job.
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Build Date 11/04/03
277.1 RWHP 301.2 RWTQ 1/28/04 SAE Stock
294.2 RWHP 314.0 RWTQ 1/25/05 SAE.
12.61@108MPH 04/16/06
Magnaflow Magnapaks,MRT Catted H pipe SCT Xcalibrator tune,Ported/Polished lower intake with PHP spacer,S&B 8" Powerstack filter on Lowes CAI, MGW Shifter, Strange 31 spline axles, FRPP 31 spline diff with carbon fiber clutches, FRPP 4.10 gears,17x9 and 17x10.5 Black FR500 rims, BFG drag radials
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Old 12-21-2004, 07:25 AM   #41
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Quote:
Originally Posted by BlackMach
I just wanted to say that I just got off the phone with a Rick Miller of Extrude Hone down in Irwin PA and I was thinking about volunteering my upper intake manifold to him for tooling (I would get a substantial discount of course). All told, it would take about 3 weeks (from Jan 3, 2005), and once done, Rick would report the flow percentage increase. Once the tooling is complete, the process would only take days for the other intakes sent in to him.
Extrude Hone should already have the tooling for this intake. I wouldnt let them charge you for the tooling. Our intake is the same as the 01 Cobra.

NAZ, have you dyno'd after the camshaft install?
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Old 12-21-2004, 09:06 AM   #42
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Quote:
Originally Posted by Comp Orange 04
So how do you put the intake back together after you cut the bottom off? Seems like a fairly hard aluminium weld job.
I use an epoxy for that joint.(Its rated for temps above 300 degree's.) A 1" inch band is applied around the entire perimeter of the intake for added insurance / strength. Tig welding is an option but adds tremendously to the over all cost. I'm experimenting with a special aluminum rod that uses a soldering process to adhere the base part metal together. Many are concerned about an epoxy joint, so maybe this will be an alternative which will still keep cost down.
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Old 12-22-2004, 05:56 AM   #43
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Looks good. I did mine a few weeks ago.

http://www.mach1registry.org/forums/...ad.php?t=27086

Here's the link. The pics show what I did to the lid as well.

Also, Naz's comments are good. But I didn't have the nads yet to cut the bottom off. Maybe next time.

As for power increase, I couldn't really tell, but I don't drive the car everyday. It always feels fast to me. I hope to dyno or get to the track soon.

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Old 12-22-2004, 01:46 PM   #44
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Quote:
Originally Posted by Mach1Marauder
Hush CHICKEN!
Yo Dude, the Oak Ridge Boys called, they want to put the band back together!
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Old 12-22-2004, 03:27 PM   #45
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Old 12-22-2004, 03:30 PM   #46
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Old 12-22-2004, 10:23 PM   #47
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Mach-1 Review

Quote:
Originally Posted by Nazman




Naz

"TACH9" over at the Mach-1.org is gearing up for a port and polish intake comparson test soon after the new year. I believe he is looking to get a hold of a "PHP" , "SHM" , an Extrude hone version, mine and maybe Naz man if he can work it out? This should be a real good evaluation as they have done many good quality write ups in the past with popular bolt on's. Stay tuned!!!
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Old 12-22-2004, 10:37 PM   #48
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Sound like a very good deal. This have been long over due!

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Old 12-22-2004, 10:37 PM   #49
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Now that would disspell any rumors of performance. That is what I like - FACTS and comparisons.
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Old 12-26-2004, 12:54 PM   #50
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Ok now that Christmas confusion is over, back to porting. I have my new plug caps on order and I am contemplating cutting the bottom of the intake off. I have a friend who TIG welds and can put it back together for me. The only requests he made were a very straight, smooth cut and a perfectly clean intake. No oil, grease or grime present. Anyone can let me know the pro's and con's to this. I would also like to know the brand name of the epoxy we can use to glue also.
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294.2 RWHP 314.0 RWTQ 1/25/05 SAE.
12.61@108MPH 04/16/06
Magnaflow Magnapaks,MRT Catted H pipe SCT Xcalibrator tune,Ported/Polished lower intake with PHP spacer,S&B 8" Powerstack filter on Lowes CAI, MGW Shifter, Strange 31 spline axles, FRPP 31 spline diff with carbon fiber clutches, FRPP 4.10 gears,17x9 and 17x10.5 Black FR500 rims, BFG drag radials
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