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.

 

extrude hone ftw!!!

 

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

 

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

 

Next writeup: How to CNC machine a complete engine block

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

 

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

 

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.