2003-04 Mach 1 Registry Owners Club  

Best Mustang Parts

Go Back   2003-04 Mach 1 Registry Owners Club > "GO" Discussions > Engine & Drivetrain (Including trans & rear axles)

Reply
 
Thread Tools Display Modes
Old 12-15-2004, 02:46 PM   #1
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
Talking Going to start my port and polish of my intake tonight

Hopefully my PHP spacer will be on the way in the next two weeks so I decided to start the polish job today. I will post some pictures (hopefully as good as Rcodegirl's) and we will see how it comes out. Then after the spacer install, need to head over to Mach 1 Cal Man for a tune.

Here is a good link I found on how to dissassemble the upper and lower intake. It's for a 01 Cobra but it should be pretty darn close.

Pics to come....

http://members.cox.net/tazcobra/int_inst.pdf
__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-15-2004, 07:25 PM   #2
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
The disassembly

Well here goes:

Before I started:



Shaker off. Don't forget the 2 bolts on the side



Shaker frame off:



Upper intake off. I left the EGR on the tube.

__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-15-2004, 07:26 PM   #3
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
This is what I did with the fuel rails, I didn't like leaving them unprotected.



Another shot with fuel rails off:



Side view. You can never have too many pictures of how stuff looks

__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-15-2004, 07:28 PM   #4
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
All off. The lower intake cleared the EGR !! I will still probably wind up taking it off with the PHP spacer



And there they are !! I will start later tonight or tomorrow.



On a side note, is it ok to leave the hood up on the prop rod for a week or so?

I will add some more pics as I attempt the polish job.
__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-15-2004, 10:09 PM   #5
loathe
SHAKEN, Not Stirred!
 
loathe's Avatar
 
Join Date: Feb 2004
Location: Pearland, TX
Posts: 1,408
you sir are a wizard:p its looking so clean
loathe is offline   Reply With Quote
Old 12-15-2004, 10:17 PM   #6
PapaTango
Flyin' Under the Radar
 
PapaTango's Avatar
 
Join Date: Sep 2003
Location: Southern Pines, North Carolina
Posts: 320
A couple of Q's:

Are you planning to cut the intake open to reach the entire runner, or just grind on what you can reach from the top?

Do all of the various gaskets look like they can be reused when you bolt everything back up?

Isn't it amazing how oily and dirty the inside of something is that is only supposed to flow filtered air!

Take some before and after pics of the internal surfaces.
__________________
03 Mustang MACH 1
Mods:
MAF Screen & Air Silencer Delete
K&N Air Filter
Flowmaster "American Thunder" Exhaust System
Magnaflow X-Pipe w/ Cats
FRPP 4.10 Gears
BBK Progressive Rate Lowering Springs
Diablo Predator Performace Tuning
PHP Intake Spacer
IAC Restrictor Plate (Thanks to Mach1Canuck!)
UPR "Blue Thunder" Shifter w/Billet stick
Valentine Radar Detector
XM "Roady2" Satellite Radio
Lots of Zaino!

"Traffic lights set at 35 mph are also set at 70 mph!"
PapaTango is offline   Reply With Quote
Old 12-15-2004, 10:50 PM   #7
ITLRUN
Cloud Nine
 
ITLRUN's Avatar
 
Join Date: Mar 2003
Location: Adairsville, GA
Posts: 3,132
What kind of gains to you expect to see by "porting" or polishing the intake?

I not 100% convienced that it will help. I have heard that it will and I have also heard that it wont. I'm not trying to start a flame war at all. Im interested in proof positive. I have thought about working mine, but not sure its worth any gians at all.
__________________
Joe Charles

HiPoJoeCharles.com

Please "LIKE" my Facebook Fan Page!
ITLRUN is offline   Reply With Quote
Old 12-15-2004, 11:01 PM   #8
ITLRUN
Cloud Nine
 
ITLRUN's Avatar
 
Join Date: Mar 2003
Location: Adairsville, GA
Posts: 3,132
Quote:
Originally posted by PapaTango
A couple of Q's:

Are you planning to cut the intake open to reach the entire runner, or just grind on what you can reach from the top?
There are plugs (like a freeze plug) in the bottom of the manifold that can be removed to access the bottom of the runners.

Quote:
Originally posted by PapaTango
Do all of the various gaskets look like they can be reused when you bolt everything back up?
They intake gaskets are reuseable if you are careful with them. I am a bit hesitant to reuse them. After all they are fairly inexpensive.

Quote:
Originally posted by PapaTango
Isn't it amazing how oily and dirty the inside of something is that is only supposed to flow filtered air!
Not only filtered air, but the intake is also injesting the "dirty / oily" air from the PCV Valve on the LH head and the vent on the RH head. I have vented mine to the atmoshpere with small filters to try to keep this contamination to a minimium.
ITLRUN is offline   Reply With Quote
Old 12-15-2004, 11:55 PM   #9
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
Quote:
Originally posted by PapaTango
A couple of Q's:

Are you planning to cut the intake open to reach the entire runner, or just grind on what you can reach from the top?

Do all of the various gaskets look like they can be reused when you bolt everything back up?

Isn't it amazing how oily and dirty the inside of something is that is only supposed to flow filtered air!

Take some before and after pics of the internal surfaces.
I am going to pull the freeze plugs/casting access ports out and do some work inside also.

All the gaskets look mint, but I am going to get new ones. No reason not to while it is all apart.

the biggest culprit is the PCV valve pulling oil in. I am also seeing some marks from my EGR line.

Plenty of pictures to come!!
__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-15-2004, 11:57 PM   #10
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
Quote:
Originally posted by ITLRUN
What kind of gains to you expect to see by "porting" or polishing the intake?

I not 100% convienced that it will help. I have heard that it will and I have also heard that it wont. I'm not trying to start a flame war at all. Im interested in proof positive. I have thought about working mine, but not sure its worth any gians at all.
I agree with you. I may not see any gains from this folly, but heck why not? The car is basically in storage and I already had to do 1/2 the work getting the upper intake off. Plus you never know. Stranger things have happened.
__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-16-2004, 12:00 AM   #11
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
What really baffles me is the 6 holes to 8 setup they have in this intake? Why the heck is it like that? Was there that much difference in 6 holes vice 8?
__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-16-2004, 12:07 AM   #12
ITLRUN
Cloud Nine
 
ITLRUN's Avatar
 
Join Date: Mar 2003
Location: Adairsville, GA
Posts: 3,132
BTW, nice pics... now go get busy!!! lol :p
ITLRUN is offline   Reply With Quote
Old 12-16-2004, 12:53 AM   #13
mustangmike2003
Registered User
 
mustangmike2003's Avatar
 
Join Date: Oct 2004
Location: Chicago
Posts: 2,307
How many miles do you have on that intake?
__________________
03 Torch Red Mach 1 5speed

Blown Motor Mod
mustangmike2003 is offline   Reply With Quote
Old 12-16-2004, 02:47 AM   #14
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
Quote:
Originally posted by mustangmike2003
How many miles do you have on that intake?
9500 miles
__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-16-2004, 02:50 AM   #15
Mach1_cal_man
Bullitt/Mach1 Calibrator
 
Mach1_cal_man's Avatar
 
Join Date: Mar 2004
Location: Formerly MI, Central IL now
Posts: 147
Erik,

This brings back memories!

I noticed you intake showed signs of oil pullover through the PCV system . My intake was pretty clean with only 2300 miles on the ODO when I did mine although there was some oil in the lower which is normal.

I think I have some spare gaskets if you need them too.

Good luck with this!

__________________
Brian Y.
Bullitt/Mach1/05 GT Ford Calibrator
sonicmach1.com
2004 Blue M/T --> Sold May 2009

2003 Cobra Build Thread
650+ RWHP

Last edited by Mach1_cal_man; 12-16-2004 at 02:56 AM.
Mach1_cal_man is offline   Reply With Quote
Old 12-16-2004, 02:55 AM   #16
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
Thanks Brian, I think this will be my most challenging thing to date. Hopefully I will have it done by new years, then we can look into getting a tune done. With the intake filter mods I did and this I definately want to get my A/F checked as a minimum to make sure I didn't lean her out too much.
__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-16-2004, 03:45 AM   #17
MA-MACH1
Thread Killer
 
MA-MACH1's Avatar
 
Join Date: Oct 2004
Location: Morrisville, NC
Posts: 1,050
awesome pics - looks like there is a lot of restriction in that lower intake - would a Cobra R intake fit? I think I remember seing a pic where all 8 inlets are trumpets inside a big casing. BMW do something like that on the M5 I believe (and that company seems to know a thing or two about tuning stock engines) - If I could I'd throw the stock intake out and try to fab something a bit freer flowing (though if you lose that longer intake I guess you'll potentially lose that nice bottom end torque we get). I don't think the polishing makes much difference - the air-flow turbulence could even benefit a little with combustion from unpolished intakes, but the porting has gotta help. I'm curious about the potential power gains however as they are essentially free - dyno results please!!!!!
__________________
03 Mach 1 Torch Red 5 sp IUP
98 GT (long gone)
Post killing skills - A+
MA-MACH1 is offline   Reply With Quote
Old 12-16-2004, 04:06 PM   #18
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
Well the process has started. Let me tell you getting those dang port plugs out was a pain in the ***! Tried many a technique and when all the smoke cleared I wound up drilling a pilot hole, making it bigger with screwdrivers prying up at the same time, then forcing it out with vise grips. Here is a picture (I believe) of the part number for the freeze plugs:



Here is what a plug looks like after it is forcefully removed:



All the plugs out:



And started the process. I need to go out and get a little rougher grit set of stones for my dremel so I will post more later. This is going to take a while....

__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-16-2004, 10:15 PM   #19
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
Well, grinding continues. I have a couple in process pics I'll post up later. Most of the flashing to be removed so far is in the first bends heading down to the bottom. Looks like they stick something square down 4 of the six openings to remove the intake from the mold. Lots of stuff to remove there. Also I removed a lot of metal on the sides leading into the holes. I did some work on the flutes on the bottom, but mine were actually in good shape. I don't know if I want to thin out that area too much due to the fact I am having a hard time getting into the center of the intake passage.

I removed all the rough stuff from the top of the runners and I will set to smoothing later tonight.
__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-16-2004, 11:03 PM   #20
rjw158
Registered User
 
Join Date: Aug 2002
Location: Southeast Michigan
Posts: 671
You need those tapered emery cones to get into the corners, that's what I used and they worked pretty well.
rjw
rjw158 is offline   Reply With Quote
Old 12-16-2004, 11:21 PM   #21
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
Quote:
Originally posted by rjw158
You need those tapered emery cones to get into the corners, that's what I used and they worked pretty well.
rjw
Yup picked up a set earlier. Thanks for the tip. More pics to come later.......
__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-16-2004, 11:47 PM   #22
rjw158
Registered User
 
Join Date: Aug 2002
Location: Southeast Michigan
Posts: 671
What did you end up doing with the top cover? I deburred, blended the corners then polished it, if I can find a pic i'll post it.
rjw
rjw158 is offline   Reply With Quote
Old 12-16-2004, 11:52 PM   #23
Comp Orange 04
Registered User
 
Comp Orange 04's Avatar
 
Join Date: Nov 2003
Location: Normal, Illinois
Posts: 461
That is what I am thinking also, I am not going to polish the outside, just clean up the inside, around the throttlebody and call it good.
__________________
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
Comp Orange 04 is offline   Reply With Quote
Old 12-17-2004, 12:13 AM   #24
rjw158
Registered User
 
Join Date: Aug 2002
Location: Southeast Michigan
Posts: 671
Exactly, just blend around the divider after the TB and polish the rest, my top cover ended up looking like a mirror. On the bottom mostly deburring and blending. It looks like they just ran an end mill down into the runners on the lowerto clean up the seam on the casting.
rjw
rjw158 is offline   Reply With Quote
Old 12-17-2004, 12:42 AM   #25
Slicksaleen
DSG is the Fastest
 
Slicksaleen's Avatar
 
Join Date: Sep 2002
Location: Northern IL
Posts: 256
Quote:
Originally posted by Comp Orange 04
This is what I did with the fuel rails, I didn't like leaving them unprotected.



Another shot with fuel rails off:



Side view. You can never have too many pictures of how stuff looks

ALDI RULES! Keep the pics coming, very nice writeup so far
__________________
Support the Pipe Layers Union!! Click Here
#344924
DSG 5-speed IUP
Current Mods:
Bassani Cat-back Bassani off road X K&N Air Charger
PHP Spacer FRPP Driveshaft MM full length subframes
"GT" Coil Covers MGW Shifter Draglite XP's SS lines
Drilled&Slotted Rotors HPS Pads Meizere H20 Pump
Diablo Predator 2000 R P/S Pulley Eaton Diff 4.10's
Superior 31spline My Mustang Trunk Lid Mat
Slicksaleen is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -4. The time now is 12:52 AM.


Powered by vBulletin® Version 3.8.4
Copyright ©2000 - 2018, Jelsoft Enterprises Ltd.
(c) 2002-2013 Mach1Registry.com

<