Been meaning to get to it for too long. I found the lost photos so here we go
To start, the tool list.
Dewalt DW887 grinder. Worth every penny
non ferrous bits, the cutters. I buy long and short versions and cut the 6" units to 4-5". 3/8" tree shape is my favorite.
1/2" x 2" 80 grit and 120 grit sand rolls, the fat ones bend mandrels.
Mandrels for scotch bright balls and the sand paper rolls, long and short versions.
The bit on the left is for aluminum, on the right is for iron.
Taking great care to line up the holes with the gaskets mark both ends. Then look at what you did, you often see core shift at this point which is fine. Get your bits ready for cutting. Always use short, easy to control bits for cutting to the edges. Long bits are used only when you can't reach as they fail to easy.
Always make sure to have light in the runners and they start cutting. Make sure to use the C clamp to hold the manifold.
I like to use the 80 grit sand paper rolls and both length mandrels at this point, this end of the intake goes pretty fast. I widen the manifold down into the runner. I make a nice inside turn in the manifold too to help flow. Then sand the whole runner as far as you can.
The head side is the toughest. The bumps are long on the inside and don't match the outside. So you need to pinch the dents / bumps to check thickness. I can handle this by touch, if you don't feel safe you can buy testing clamps cheap. The top is easy, see how wide it is between the injector hole and the top of the runner? Split the difference and blend back at least an inch. Then widen to the gasket, easy but go slow. Blend in 3" on the sides. It is ok to leave a little ridge from the cutter on the bumps at this point.
now switch over to 80 grit and sand the whole runner, going long and short mandrels.
Then do the same thing with the 120 grit.
Next up is the polish balls, I like to use medium and fine. Tough to get medium in the ports lol. The fine ones seam to work best but don't hit the rough spots as well.
Next I use the belt sander, very lightly to sand the surfaces. This cleans and flattens them.
Lastly I stick the plenum on and check my work, nice funnel into the runners, no sharp edges or corners for the air to get in is key.
To start, the tool list.
Dewalt DW887 grinder. Worth every penny
non ferrous bits, the cutters. I buy long and short versions and cut the 6" units to 4-5". 3/8" tree shape is my favorite.
1/2" x 2" 80 grit and 120 grit sand rolls, the fat ones bend mandrels.
Mandrels for scotch bright balls and the sand paper rolls, long and short versions.
The bit on the left is for aluminum, on the right is for iron.
Taking great care to line up the holes with the gaskets mark both ends. Then look at what you did, you often see core shift at this point which is fine. Get your bits ready for cutting. Always use short, easy to control bits for cutting to the edges. Long bits are used only when you can't reach as they fail to easy.
Always make sure to have light in the runners and they start cutting. Make sure to use the C clamp to hold the manifold.
I like to use the 80 grit sand paper rolls and both length mandrels at this point, this end of the intake goes pretty fast. I widen the manifold down into the runner. I make a nice inside turn in the manifold too to help flow. Then sand the whole runner as far as you can.
The head side is the toughest. The bumps are long on the inside and don't match the outside. So you need to pinch the dents / bumps to check thickness. I can handle this by touch, if you don't feel safe you can buy testing clamps cheap. The top is easy, see how wide it is between the injector hole and the top of the runner? Split the difference and blend back at least an inch. Then widen to the gasket, easy but go slow. Blend in 3" on the sides. It is ok to leave a little ridge from the cutter on the bumps at this point.
now switch over to 80 grit and sand the whole runner, going long and short mandrels.
Then do the same thing with the 120 grit.
Next up is the polish balls, I like to use medium and fine. Tough to get medium in the ports lol. The fine ones seam to work best but don't hit the rough spots as well.
Next I use the belt sander, very lightly to sand the surfaces. This cleans and flattens them.
Lastly I stick the plenum on and check my work, nice funnel into the runners, no sharp edges or corners for the air to get in is key.