Porting Update

[LGAFF]

Thought I would give everyone the update on porting project. I have learned a few things. I did the intake plenum with a dremel soft metal attachment on a flex shaft. This was great for the short turn and immediately inside the runner opening. It was not good for hitting the long turn due to the angle, and left some small marks, which I am going to clean up with a flap wheel later. If I did this over I would focus on using a flap wheel or other device on the long turn as the material removed is minimal.

After roughing everything out I went back, and used a barrel sander on a drill to try and keep everything "rounded" and symmetrical, this worked well. Finally I took some sandpaper and hit the short turn radius leading into the plenum body using my fingers. Both the drill and dremel worked surprisingly fast.....WD40 or grinders grease doubles the speed with which material is removed. I should have everythng cleaned up by the weekend.

Here are a few few photos.......hopefully I am not a total hack.

1)Photo of runners: note I have not flushed the material out of the body as of yet

http://i134.photobucket.com/albums/q...f/DSC02390.jpg

2)This is the 36mm fooseball in the runner.
http://i134.photobucket.com/albums/q...f/DSC02393.jpg

3)Straight shot down the runner, notice the long turn has a few "gotcha" spots I am going to hit these with a flap wheel to smooth them out

http://i134.photobucket.com/albums/q...f/intakesd.jpg


4)This is the one spot to watch out for, the material is thinner here than in other areas, I have one spot I am going to have some material added

http://i134.photobucket.com/albums/q...f/thinspot.jpg

Let the flaming begin.

LGAFF
92 ZR1
#234

How many hours do you have in, and how far along in the job do you think you are?

[LGAFF]

The start was so slow, I was really trying to work down the short turn with files, etc. its hard to say.......if I charged what you charged(obviously I'm a hack compared to you) I would be in violation of the fair labor standards act as I would be making far less than minimum wage. If I went into the next one knowing my mistakes on this one I would say I could do a plenum in 12- 15 hours. Not knowing the proper tools definately has its price to be paid in quality and speed.

Injector housing is yet to be seen. Will also be port matching the heads.

LGAFF
92 ZR1
#234

Originally Posted by LGAFF

The start was so slow, I was really trying to work down the short turn with files, etc. its hard to say.......if I charged what you charged(obviously I'm a hack compared to you) I would be in violation of the fair labor standards act as I would be making far less than minimum wage. If I went into the next one knowing my mistakes on this one I would say I could do a plenum in 12- 15 hours. Not knowing the proper tools definately has its price to be paid in quality and speed.

Injector housing is yet to be seen. Will also be port matching the heads.

LGAFF
92 ZR1
#234

I just wanted people to know. It's a steep learning curve. So far looks good. Keep an eye on port alignment. By the time you invest in tools and the time to learn and make a few mistakes it can be costly.

[LGAFF]

I am trying the poor mans version, certainly what you do is a bargain. Using smaller tools: dremel, etc is like trying to fix a body panel with a small sanding block, smoothing everything out is difficult. You are correct on cost, air grinder sucks unless you have a 60+ gallon tank. Electrical grinder is $160 plus all the bits. Its also a nasty mess.

Proof will be in the pudding this summer to see if I can best my 12.54@117.25!

LGAFF
92 ZR1
#234

[Polo-1]

you got a long way to go

[Locobob]

Originally Posted by LGAFF

Injector housing is yet to be seen. Will also be port matching the heads.

LGAFF
92 ZR1
#234

Looks pretty good so far. Here's a hot tip that may be a bit late: I always check the port match first - usually the parts are skewed in one direction so checking the port alignment first keeps you from having to remove more material than intended i.e. ending up with larger ports than you planned on.