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:
http://i47.photobucket.com/albums/f1...h/DSC08454.jpg
http://i47.photobucket.com/albums/f1...h/DSC08453.jpg

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.
http://i47.photobucket.com/albums/f1...h/DSC08455.jpg

measurement before porting:
http://i47.photobucket.com/albums/f1...h/DSC08456.jpg

oem tb measurement:
http://i47.photobucket.com/albums/f1...h/DSC08457.jpg

replacement tb measurement:
http://i47.photobucket.com/albums/f1...h/DSC08458.jpg

comparision between the two... i will have to modify the replacement to add the map sensor on top. shouldn't be hard to do.
http://i47.photobucket.com/albums/f1...h/DSC08459.jpg
http://i47.photobucket.com/albums/f1...h/DSC08460.jpg

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.
http://i47.photobucket.com/albums/f1...h/DSC08462.jpg

finished dimesion (slightly larger than the tb):
http://i47.photobucket.com/albums/f1...h/DSC08463.jpg

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.
http://i47.photobucket.com/albums/f1...h/DSC08465.jpg
http://i47.photobucket.com/albums/f1...h/DSC08464.jpg

Re: How to: Bore your intake manifold
 

good work man. I wish I had all those tools! Do you have any way of working the runners?

Re: How to: Bore your intake manifold
 

extrude hone ftw!!!

Re: How to: Bore your intake manifold
 

beats using a ------- dremel like i got to :y

Re: How to: Bore your intake manifold
 

no ----, title should read : How to bore your IM if you have sick ass tools

Re: How to: Bore your intake manifold
 

Next writeup: How to CNC machine a complete engine block :S

Good writeup, but we need a cheap nog how to do it with a die grinder/hone/CDM power drill writeup. O0

Re: How to: Bore your intake manifold
 

If you need a writeup for that, you fail.

Re: How to: Bore your intake manifold
 

The afro disappears when you quote it? How will they know I was speaking blackanese?

Re: How to: Bore your intake manifold
 

http://www.pixeljoint.com/files/icons/afro_black.gif

Quote proof

Re: How to: Bore your intake manifold
 

Is it a bitch to set that flycutter up to the right radius? I have some machining experience but haven't done any boring or stuff like that.

You shop looks sick. Someday I want to have my own automotive machine shop, parts store.