Wow Aaron, thats cool. Now can you show us how to do it with easy to find cheap tools? :P

 

it could be done by hand with a dremel, you would just have to be careful and take your time. scribe a new arc to port it to before you start. also, be sure to spray the burr with some wd40 every once in a while to prevent it from clogging.

it isn't that difficult, just pull it out a bit, start a cut about a couple mm deep, then measure before continuing and then make any necassary adjustment and finish the cut.

 

should have went a little bigger on the intake, like 68mm, if there was enough meat.

 

 

Sick work Aaron, i dont know you you find the time man. Thats awesome that you take the time to post up as well. I love those fly cutters, If you use them right and do a climb cut you can get a real nice finish on cuts of a few thousandths. they arent that great for removing any significant amount of material. When you went for the Center of the TB, did you just indicate from the edge and just move the mill half of the measured distance from your caliper?

Final product looked great !

 

i put a dial indicator in the spindle, then rotate it in a circle until i get a zero reading in 4 directions the table moves. it takes a bit of tinkering to get the indicator at just the right spot to match the diameter of the hole, but it is the most accurate way. another way would be to use an edge finder in one axis of movement picking up the two edges of the arc then just splitting the difference, and then doing the same in the perpendicular axis.

 

Nice job. I gotta do this to. But I got a 75mm TB. Any tips?

 

you will probably need to weld up half of the iacv ports where the 75mm will run into it before you port it.

 

well if your doing it by hand have fun spending a day on it

 

With the right tools, it can be done in about 20 minutes.

The only question I have.... you centered up to the existing hole, that you said wasn't very true. Why didn't you center up to the center of the bolt pattern, rather than the center of the hole?

...it's probably splitting hairs though.