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Old 01-14-2005, 01:23 AM   #76
351c.i.d
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Re: Going to start my port and polish of my intake tonight

suuuuuuubscribing!
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Old 01-14-2005, 09:17 AM   #77
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Re: Going to start my port and polish of my intake tonight

I wish I had the marbles to do that! The job looks excellent. I have followed this from the first thread and am interested in the results!
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N2O Best Time: 60 ft: 1.661; 1/4: 11.748 @ 117.00
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Old 01-14-2005, 02:12 PM   #78
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Re: Going to start my port and polish of my intake tonight

The welds look great! That is not the easiet weld to do. I am very interested to hear your results also.
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Old 01-14-2005, 06:21 PM   #79
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Re: Going to start my port and polish of my intake tonight

Me too!
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Old 01-14-2005, 06:24 PM   #80
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Re: Going to start my port and polish of my intake tonight

OK here is Steve's info. He is the one that welded up my intake and also powder coated my friends BMW motorcycle frame. This is for all the people in the Chicago area. I am not advertising for him, just providing a reference if anyone needs this sort of work done.

His services include: Powder coating, welding (TIG/MIG, stainless, mild/cast steel and aluminum and titanium), Plastic media blasting/stripping. He does mail order and UPS work also.

He has excellent prices and a quality product. Contact Steve at Team Clean (630) 896-TEAM. He is located in Montgomery (Aurora area).

So back to tech, I am heading down to put my plugs in then reinstall my intake tonight. Hopefully I remember where everything goes.....
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2004 Competition Orange
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 01-14-2005, 09:32 PM   #81
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Re: Going to start my port and polish of my intake tonight

The cup plugs are in. Boy do they SUCK. I think they are the exact size of the hole. Be very carefull putting them in. I used a hammer to put them in, a lot of cuss words to vent my anger and high temp red loctite to seal them in. I would post a picture, but it looks like the one on page one with them in so out I go.....
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2004 Competition Orange
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 01-15-2005, 01:56 PM   #82
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Re: Going to start my port and polish of my intake tonight

Lower intake is back in and fuel rails reattached. I will have the upper intake on later today and hopefully get my brakes bled from the line lock install. Maybe just maybe I can get her on the road today for a test drive.....
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2004 Competition Orange
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 01-15-2005, 11:59 PM   #83
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Re: Going to start my port and polish of my intake tonight

SHE LIVES!!!!!!!!!!!!!! Well fired her up tonight.

I only forgot 2 vacuum lines (one under the throttle body and the one on top of the intake lid. Trust me the car will not stay running with either of these off.

I went and rechecked my pictures and was able to find the problem. So here are my lessons learned from this whole project.

1) Take lots of pictures for reference. I took over 100 pictures.

2) Listen to many people before making decisions. You guys helped me out in many ways.

3) Take your time. This is not a quick or easy project.

4) Cut the bottom off of the intake. You can do so much more with it off than with it on.

5) Before doing #4 make sure you have a way to get it back on. I cut mine before lining this up. Lukily I found someone and for a good price.

6) Don't expect to pick up 30 HP. I would like to get some but if I don't I will not be disappointed. I learned a lot about my car and how it comes apart and goes together. To me that makes this all worth it.

I appreciate all the replies and views this post has received. It lets me know that you were interested and that fueled me on. As I said before I am not a professional at this, I just decided to do it. The learning curve was steep.

I would like to thank Nazman, Orange Blast, Mach1 cal man, Rcodemach1 and Itlrun for their input and assistance. A lesser product surely would have turned out without them.

Well, I'll bleed my brakes tomorrow and get it out on the road for a small test. Then hopefully to the dyno in about 2 weeks. I will post an update when I get it.

Thanks all.
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2004 Competition Orange
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 01-17-2005, 03:06 PM   #84
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Re: Going to start my port and polish of my intake tonight

Well it runs real well. I was able to get her out today for a spin today. Definately felt more responsive. I can't keep traction >1/2 throttle in 1st or second. I am sure most of that is due to the 14F temperatures out here and skaterbacks. But it is something it hasn't done before. Shoot even the line lock works . Now to get it on the dyno and see what it does. Then comes 4.30 gears and 31 splines...... oh and lower control arms.
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2004 Competition Orange
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 01-18-2005, 05:20 AM   #85
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Re: Going to start my port and polish of my intake tonight

Glad to hear everything went ok.

I told you it was easy!

Best of luck.

Naz

Quote:
Originally Posted by Comp Orange 04
Well it runs real well. I was able to get her out today for a spin today. Definately felt more responsive. I can't keep traction >1/2 throttle in 1st or second. I am sure most of that is due to the 14F temperatures out here and skaterbacks. But it is something it hasn't done before. Shoot even the line lock works . Now to get it on the dyno and see what it does. Then comes 4.30 gears and 31 splines...... oh and lower control arms.
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Old 01-22-2005, 05:39 PM   #86
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Re: Going to start my port and polish of my intake tonight

Question for the experienced guys. I have made several observations. It would appear that the factory built in a bunch of clearence around the back of the injector (between the injector and the intake). This is the area that protrudes into the port. When you guys open up the port just behind the injectors, how agressive do you get?

Our cars use a much smaller (diam) injector and do not need as much clearance. Have you thought about adding more material to this area just behind the injector (on the outside of the intake) so that you could remove more of the bump inside the port?

I have and did. Unfortunately, I do not have any pics to share with you guys as my car is currently at MV Performance (100 miles from me) waiting to be tuned.
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Old 01-22-2005, 06:01 PM   #87
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Re: Going to start my port and polish of my intake tonight

Here is a pic of the area Joe is talking about. You can remove stock up to the red line. Any further and you might break through the wall. Which may disrupt the spray pattern of the injector and a trip to your welder. The black line shows the original cast bump and the blue area is where the casting is champhered for the injector to spray. As you can see, there is quite a bit of stock that can be removed.
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Old 01-22-2005, 06:43 PM   #88
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Re: Going to start my port and polish of my intake tonight

I removed a bunch of material from this area. I did not remove the entire bump, but I did remove more than enough to expose the material I added. I really wish that I had taken pictures of this. After the manifold was cleaned, the acid I was using clearly showed the fresh alum as a different color. It would have made for interesting conversation.
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Old 01-22-2005, 07:30 PM   #89
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Re: Going to start my port and polish of my intake tonight

Normally, I feel like I know a good bit about my car, and 4.6's in general. After reading through this thread, I found out that I know very little................
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Old 01-23-2005, 12:35 AM   #90
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Re: Going to start my port and polish of my intake tonight

What kind of saw did you guys use to cut the lower off?
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Old 01-23-2005, 01:07 AM   #91
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Re: Going to start my port and polish of my intake tonight

Quote:
Originally Posted by rjw158
What kind of saw did you guys use to cut the lower off?
rjw
I took mine to a machine shop and they had a auto feed saw do it. It is very important to have a smooth, continous cut done. Also make sure they use a thin blade to minimize how much material is removed.
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2004 Competition Orange
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 01-23-2005, 01:17 AM   #92
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Re: Going to start my port and polish of my intake tonight

We have a large vertical auto feeder at work, I was thinking of using it to cut mine. How deep are you cutting from the bottom around 2"?
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Old 01-23-2005, 02:56 AM   #93
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Re: Going to start my port and polish of my intake tonight

Just waiting for the results
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Old 01-23-2005, 05:34 AM   #94
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Re: Going to start my port and polish of my intake tonight

Quote:
Originally Posted by rjw158
We have a large vertical auto feeder at work, I was thinking of using it to cut mine. How deep are you cutting from the bottom around 2"?

Use the wire harness tab at the back of the manifold as a
start guide. I simply use a staight edge and a colored wax pencil to draw a line around the entire perimeter. Start the line 1/8" below the tab. It should time out at the front of the intake where there appears to be a seam.

I cut all mine by hand using a hack saw. It takes me 20 minutes and the cut looks bandsaw quality! The hack saw will get you about half way to the center from each end. With the center portions left, I use a straight handled blade holder hack saw to join the cuts. It does not require alot of muscle, just patience. Anyone can do it this way! Well the Pug has not caught on yet...
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Old 01-23-2005, 07:24 AM   #95
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Re: Going to start my port and polish of my intake tonight

Quote:
Originally Posted by Orange Blast
Here is a pic of the area Joe is talking about. You can remove stock up to the red line. Any further and you might break through the wall. Which may disrupt the spray pattern of the injector and a trip to your welder. The black line shows the original cast bump and the blue area is where the casting is champhered for the injector to spray. As you can see, there is quite a bit of stock that can be removed.
...

Last edited by Nazman; 10-16-2007 at 07:05 PM.
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Old 01-23-2005, 01:30 PM   #96
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Re: Going to start my port and polish of my intake tonight

Thanks for the tip Orange Blast, now ya got me thinking. A cut off wheel in the dremel might be the ticket here.
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Old 01-27-2005, 12:02 AM   #97
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The verdict is in !!

Well after the smoke has cleared looks like the port job was a wash. Initial pull was 287.6 RWHP and 303.4 RWTQ. That is close to my final dyno of 285 RWHP and 306 RWTQ after my exhaust mods. These were done on different dynojets so there will be a slight variance in the numbers.

I think I will see the benefits of the port job when/if I get some long tube headers. But in this thread:

http://www.mach1registry.org/forums/...ad.php?t=29396

I have posted the dyno sheet. VERY good gains after the tune in area under the curve. SCT is selling a quality product. Plus having the man who calibrated the Mach 1's computer do your tune is also a benefit! So heres to you Mach 1 Cal Man

I learned a lot. We had a great supporting cast of pictures and insights from fellow Machers and Cobra owners during the whole project and dang if I didn't learn a lot about my engine.

So I am sure people will ask "Was it worth it?" And I will say "You bet it was" I may not see it now but I know it will show itself as I slowly continue to evolve the car. Who knows... maybe I will shop for some headers for next winters project.... pics to follow

Thanks for all the support, and those of you in the Illinois/Missouri area, think about Mach 1 Cal man for all your tuning needs and R&T Unlimited for their excellent support.
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2004 Competition Orange
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 02-07-2005, 09:34 PM   #98
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Re: Going to start my port and polish of my intake tonight

great job. and dont make the intake runners smooth cuz you dont want the air to just flow in there you want it to spiral in there and mix with the fuel. so just clean the edges up and kinda leave em rough. great work tho none the less
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Old 02-08-2005, 12:35 AM   #99
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Re: Going to start my port and polish of my intake tonight

How about if you put 8 Spiramax into each of the runners? That will make the air spiral!!! Thats about 60RWHP gain and 45MPG!!!
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Old 02-09-2005, 03:32 AM   #100
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Re: Going to start my port and polish of my intake tonight

Oh the tornado I still laugh when I see the tv ad....
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