How to: Bore your intake manifold
#1
How to: Bore your intake manifold
i may not use this intake manifold, but i thought i might bore it out just incase i don't get around to building a new one before the engine is in the car.
setup on mill:
first setup the manifold so that the t/b mounting surface is flat, then indicate the port to find the center, or as close to center as you can get. the stock casting isn't perfectly round.
measurement before porting:
oem tb measurement:
replacement tb measurement:
comparision between the two... i will have to modify the replacement to add the map sensor on top. shouldn't be hard to do.
i couldn't fit a proper boring head in the limited travel of my mill, so i opted to use this small flycutter. here it is making the second cut. worked fine with the quill feed engaged.
finished dimesion (slightly larger than the tb):
as you can see the casting isn't exactly even all around so make sure you go deep enough to get all the material to make it a smooth transition.
setup on mill:
first setup the manifold so that the t/b mounting surface is flat, then indicate the port to find the center, or as close to center as you can get. the stock casting isn't perfectly round.
measurement before porting:
oem tb measurement:
replacement tb measurement:
comparision between the two... i will have to modify the replacement to add the map sensor on top. shouldn't be hard to do.
i couldn't fit a proper boring head in the limited travel of my mill, so i opted to use this small flycutter. here it is making the second cut. worked fine with the quill feed engaged.
finished dimesion (slightly larger than the tb):
as you can see the casting isn't exactly even all around so make sure you go deep enough to get all the material to make it a smooth transition.
#2
I just did one yesterday made the bore 67 mm using a boring bar we set it up on a mill table horizontally. The opening is kind of egg shaped as you said.
I wish I took pics of the job like you. I will take a few of the new 67 mm opening and post them up
Nice work
I wish I took pics of the job like you. I will take a few of the new 67 mm opening and post them up
Nice work
#4
Originally Posted by hisownhero,Jul 20 2007, 08:32 AM
Nice job. Is that DH Racing T body 66mm straight bore or tapered? Any welding on the manifold?
#6
Here is the one we did to 67 mm
That is a stock TB
The car it's going on is N/A if it were FI a little bit of a weld job maybe needed to keep the gasket from blowing out.
Don't meen to thread jack, just showing what a 67 mm bore looks like without any weld work done
That is a stock TB
The car it's going on is N/A if it were FI a little bit of a weld job maybe needed to keep the gasket from blowing out.
Don't meen to thread jack, just showing what a 67 mm bore looks like without any weld work done
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#8
Originally Posted by weiRtech,Jul 20 2007, 02:29 PM
so by weld work, i'll assume you mean on the iacv ports?
#9
Originally Posted by SpitfireS,Jul 20 2007, 10:13 AM
Nice work, great pictures
Do you have that mill at home?
Do you have that mill at home?
i can see why welding might be required. i can also imagine it would be a real pita to weld that area. welding cast alum is never fun unless it is new.
i was surprised at how biased the plenum was to the #1 runner. half the tb port opens directly into it. this is mainly why i'd like to build a better one.
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