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Ground Rat
08-31-2006, 09:26 PM
I have my stock manifold off and would like to do some porting. Could someone please post some pics of a ported mani? I need to know how much material to take off and where.

Also, what tool and bits should I use for the job?

Whorse
08-31-2006, 09:37 PM
I started doing a bit of one. I don't know how to do it properly, was just messing around, but the bits I found worked were a spherical metal bit with some teeth on it for taking off the crap in there, and then a carbide bit once I was at just metal (no rust and dirt). The flexible extension for the dremel helps a lot, as does a well placed light and some kind of air circulation (compressor blowing it out or a good vacuum sucking out the other end.

John B
09-01-2006, 12:29 AM
Use a respirator or at least a dust mask. The combustion residue bulidup in the manifold is very unhealthy.:amen:

Ground Rat
09-01-2006, 03:08 AM
So you guys use a dremel? I heard they will burn up pretty quick from porting cast iron.

86lance
09-01-2006, 12:17 PM
i ported one with a dremel and the thing is still going strong today. But its kinda slow id recomend a nibbler for an air compressor.

MiniMopar
09-01-2006, 12:36 PM
Yeah, I've used dremels for cutting tiles and such and they do burn out (especially when they are forced to breath ceramic tile dust). Still, they are small and a handy tool for the job so I use them anyway and buy a new one when it croaks.

My grandfather was a woodworker and he had this hanging dremel-on-steriods thing that had a huge motor and a long flex cable with a nice, small handle on the end. Had the same 1/8" chuck as the dremel and had a lot more torque, LOL. If I ever find a similar one somewhere for cheap I'll pick it up.

t3rse
09-01-2006, 12:49 PM
i used an air die grinder with a long mandrel and a carbide bit for rough work...then stones and finally a 'cross-buff' to polish the internals (you can see your reflection)...

Well, you obviously can't reach certain parts, but in general smooth the inside as much as possible, and open up the holes, there are lips on the head side that you can remove, and I opened up the turbo side a little bit, but other than removing the lips and general smoothing, I spent the most time polishing...

you can make a dremel extention work in an electric drill, this is what I used to polish my head, but the drill did burn up eventually...

Speedeuphoria
09-01-2006, 07:31 PM
I recomend making a template of your turbine housing(after you port it out and smoothe it), then put in on the exhaust flange and make it just a little smaller/smooth transition

Ground Rat
09-01-2006, 07:42 PM
I will use a dremel and carbide tips then, thanks guys. Anyone have close up pics of a good port job on the stock exhaust manifold?

mpgmike
09-02-2006, 01:24 AM
My grandfather was a woodworker and he had this hanging dremel-on-steriods thing that had a huge motor and a long flex cable with a nice, small handle on the end. Had the same 1/8" chuck as the dremel and had a lot more torque, LOL. If I ever find a similar one somewhere for cheap I'll pick it up.
Eastwood sells just what you're talking about. It even has the foot pedal with variable speed. Cheap? $260.

How in the heck do you post pictures on this forum?

Mike

Ground Rat
09-02-2006, 02:25 AM
You have to host them somewhere first, www.photobucket.com is free. Or you can just email them to me. ground.rat@gmail.com

mpgmike
09-02-2006, 10:27 AM
Email sent.

Mike

Ground Rat
09-02-2006, 02:23 PM
Thanks Mike!



http://www.fuelslut.net/hosting/uploads/turboman1.jpg
^Is this ported?

http://www.fuelslut.net/hosting/uploads/turboman2.jpg
http://www.fuelslut.net/hosting/uploads/Exman1.gif
http://www.fuelslut.net/hosting/uploads/HPIM2081.JPG
http://www.fuelslut.net/hosting/uploads/HPIM2082_sized.JPG

If you have any more pics, please send them my way. :thumb:

Ground Rat
09-03-2006, 12:11 AM
OK, I pulled of my manifold and bought a dremel. I plan on getting a thermal coating inside an out when I'm done.


Here is what it looked like after I pulled it off.

http://i2.photobucket.com/albums/y23/groundrat2/Minivan/01.jpg
http://i2.photobucket.com/albums/y23/groundrat2/Minivan/02.jpg
http://i2.photobucket.com/albums/y23/groundrat2/Minivan/03.jpg
http://i2.photobucket.com/albums/y23/groundrat2/Minivan/04.jpg
http://i2.photobucket.com/albums/y23/groundrat2/Minivan/05.jpg


Here is what is looks like with a gasket on top.

http://i2.photobucket.com/albums/y23/groundrat2/Minivan/08.jpg
http://i2.photobucket.com/albums/y23/groundrat2/Minivan/09.jpg
http://i2.photobucket.com/albums/y23/groundrat2/Minivan/10.jpg
http://i2.photobucket.com/albums/y23/groundrat2/Minivan/11.jpg
http://i2.photobucket.com/albums/y23/groundrat2/Minivan/12.jpg


How much material do I take off? What about on the turbo side?

cordes
09-03-2006, 12:14 AM
If it were me I would really hog it out. I don't have any expertise here, but given that the ported stockers only flow about 3% over stock, I would try to maximize the return on my efforts.

Ground Rat
09-03-2006, 12:17 AM
Only 3%? Sounds like a waste of time. Maybe I should pick up a TBI manifold instead. What would be involved in making one fit on my van (.42/.48 T3)?

cordes
09-03-2006, 12:23 AM
Only 3%? Sounds like a waste of time. Maybe I should pick up a TBI manifold instead. What would be involved in making one fit on my van (.42/.48 T3)?

There is a really good thread on the TBI manifolds on here if you do a search. They are where its at if you want to put the time into it and you can weld IMO.

Ground Rat
09-03-2006, 12:53 AM
So I just need to find a place to weld the flange from my old manifold onto a TBI manifold and redo my DP?

cordes
09-03-2006, 01:21 AM
The oil return will have to be moved to the oil pan since the old drain tube sits higher than the TBI manifold will allow. Also the oil and coolant lines will need to be redone.

Ground Rat
09-03-2006, 01:50 AM
Damn, I just bought all new oil and coolant lines.

Whorse
09-03-2006, 02:03 AM
It's a bit of a project to use a TBI Manifold. I think you will have some very intersting intercooler ducting as well, but in the end the gains would be worth it.

Ground Rat
09-03-2006, 02:05 AM
Well, I guess I'll just stick with porting this stocker for now and not expect much of a gain. :(

Ground Rat
09-03-2006, 02:11 AM
On a side note, I decided to take off my SV and broke all but one bolt. :rolleyes:

http://i2.photobucket.com/albums/y23/groundrat2/Minivan/broken_bolts.jpg

cordes
09-03-2006, 11:36 AM
Were you using a map gas torch? It won't work all the time, but it will usually save a few more than that. Bummer for sure. I guess it is time to take a trip to the machine shop.

Ground Rat
09-03-2006, 04:57 PM
Were you using a map gas torch? It won't work all the time, but it will usually save a few more than that. Bummer for sure. I guess it is time to take a trip to the machine shop.
I didn't even think of using my torch actually. Oh well.




So here is what I have done so far, what do you guys think? Am I doing it right?

http://i2.photobucket.com/albums/y23/groundrat2/Minivan/13.jpg
http://i2.photobucket.com/albums/y23/groundrat2/Minivan/14.jpg


Here is the bit I'm using. Same one you guys use?

http://www.hardwarestore.com/media/product/661616_front200.jpg

cordes
09-03-2006, 05:16 PM
It looks pretty goos thus far to me. I have always picked mine up with cars when I bought them, so I have not done one myself yet. That is pretty much how I would go about it though.

Ground Rat
09-03-2006, 08:03 PM
Thanks.

http://i2.photobucket.com/albums/y23/groundrat2/Minivan/grind.jpg

Directconnection
09-03-2006, 09:44 PM
Yes, but ditch the cutter you are using. Look in a Macmaster/carr catalog or similar. The ones that are popular are shaped like a nice egg and I can't remember the name ... egg I think. Get double cut and not too long but decent length as too long they chatter really bad at higher rpms.

forcedfedmopar
09-03-2006, 10:27 PM
heres what i did, port match plus some

http://i45.photobucket.com/albums/f98/forcedfedmopar/evencloseport.jpg
http://i45.photobucket.com/albums/f98/forcedfedmopar/closeupport1.jpg

i used the same thing your using and then sanding dowls to smooth everything out.

hope it helps

Ground Rat
09-03-2006, 11:05 PM
Wow, that looks great! How did you reach so far back in the ports? I'm using the extension on my dremel and I still can't get back in there very far.

mpgmike
09-04-2006, 02:14 AM
heres what i did, port match plus some

http://i45.photobucket.com/albums/f98/forcedfedmopar/evencloseport.jpg

i used the same thing your using and then sanding dowls to smooth everything out.

hope it helps
The port shown is #3. If you look in the upper left corner you'll see the protruding wall. If you can, remove this. Not shown is a bump further back that would be bottom center of the photo. Remove this as well. There is a bump in #4 cylinder, too. These bumps are to clearance the turbo mount studs.

Mike

Ground Rat
09-04-2006, 05:45 AM
I was wondering if it was safe to remove all those. The manifold won't crack and the studs will still be fine with those three removed? What bit do you use Mike?

88ShadowTurbo
09-04-2006, 02:21 PM
You should pic up a Porting kit from Mac, they are extrememly helpful.

mpgmike
09-05-2006, 12:27 AM
I was wondering if it was safe to remove all those. The manifold won't crack and the studs will still be fine with those three removed? What bit do you use Mike?
I grind those bumps away 'till they're flush with the port surface. I have yet to break through. Worst case scenario, you break through. There's still the stud to seal things up. No cracks will happen. Many of us have been doing this successfully for many years without cracks. Your only crack issue is the side wall of #3 port. Keep things at least 0.080" thick there and you'll be safe.

Mike