port/gasket matching an intake

[grumpyvette]

the object of port matching an intake to the cylinder heads is to increase flow and decrease the potential restriction a ledge in the port runners or mismatch in port size or location may cause to air flow rates into the cylinders

(1)use machinist BLUE , to paint the area around each port in the intake to cylinder head mating surface,

http://www.highlandwoodworking.com/brow ... 4-oz..HTML
http://www.highlandwoodworking.com/brow ... rosol.html

PORT MATCHING THE INTAKE RUNNER EXIT TO THE CYLINDER HEAD PORT ENTRANCE USUALLY HELPS REDUCE RESTRICTIONS TO FLOW RATES, AND REDUCES FUEL/AIR DISTRIBUTION ISSUES

viewtopic.php?f=27&t=1831&p=9240#p9240

viewtopic.php?f=52&t=4664&p=12600#p12600


http://www.cis.udel.edu/~davis/z28/buildup/plenum/

http://www.austinthirdgen.org/index.php?pid=21

let it dry, then after aligning the gasket ,use a machinists pick,to carefully and accurately outline the gasket entrance,edge on the intake mating surface around the existing port , the area up to that scribed line needs to be cut out and smoothly blended back into the runner as far as is practical

http://www.harborfreight.com/cpi/ctaf/d ... mber=93514
(2)
get an intake gasket from a quality manufacturer to use as a pattern and use the bolt holes as your alignment guide points
you place the intake gasket to use as a pattern then you use a die grinder
http://www.harborfreight.com/cpi/ctaf/d ... mber=99698

THESE WORK OK, (BASICALLY CHEAP THROW AWAY DIE GRINDERS< BUT YOU'LL FREQUENTLY GET 3-4 intakes done before they get pitched in the trash)
with a high speed carbide burr

http://www.amazon.com/Style-degree-Radi ... B0007OTCQC
(frequently spray cutter with WD40) to prevent aluminum from sticking to the burr blades

http://www.youtube.com/watch?v=4xhgGux7d9w

http://www.youtube.com/watch?v=cFrPps-KJy8

http://image.mustangandfords.com/f/9194212+w750+st0
/mufp_0610_19_z+engine_bulding_mistakes+port_matching.jpg

http://www.circletrack.com/techarticles ... index.html

http://www.hotrod.com/techarticles/engi ... index.html

http://theamcpages.com/documents/engine ... -ports.doc

http://www.maximumraceengines.com/intak ... rting.html

http://www.automedia.com/Port_Matching_ ... 040801pm/2

http://www.allpar.com/fix/holler/porting.html

http://racingsecrets.com/speedtalk_head_porting.shtml

http://www.automedia.com/Port_Matching_ ... 040801pm/1

http://performanceolds307.tripod.com/id29.html

http://www.mustangandfords.com/techarti ... r_arm.html

Not Port Matching Intake Manifold, Heads, Gaskets
Engine Building Mistakes Port Matching


"Mark Jeffrey of Trans Am Racing mentioned this one. We don't understand this mistake because it's so obvious. Never assume cylinder-head and intake-manifold ports automatically line up, because they don't-not even when cylinder heads and intake manifolds are from the same manufacturer. Regardless of the performance you are seeking, always port-match cylinder heads and intake manifold. Port-match using gaskets on both manifold and heads. When port-size difference is significant, consider the selection of more compatible heads and manifold. Large manifold ports and small cylinder head ports (and vice versa) don't make sense because it robs power and creates disturbed airflow through the runners."

viewtopic.php?f=52&t=462

viewtopic.php?f=27&t=408&p=688#p688

in many cases the flow increase that results is small, but in a few cases significant gains can be had, in many cases even thought the gains are small its well worth doing simply because the cost and time required is fairly low and gains of 2-4 horsepower are common, in a few cases youll find badly mis-matched ports that the process can, clear up and gaining 5-8 hp or more is the results

http://www.rodandcustommagazine.com/tec ... index.html

stock un-ported runner entrances

porting helps flow significantly

 

[grumpyvette]

its always best to do things correctly and that requires the heads being off the engine, but IVE seen guys do a few minor port clean-ups with the heads on, if your interested, heres how .....maybe I have too many REDNECK MECHANIC FRIENDS

step one
remove all the rockers and push rods, use paper towels and lightly spray and degrease the lifter valley

step two

cover the lifter gallery with a carefully cut section of plastic sheet and lots of duct tape, then tape a short curved 1/2" section of electrical conduit into the shop vacuum hose to use as a collector nozzle, to increase port velocity and allow it to enter the intake port

step three
pack the ports with paper towels then place a plug of beeswax over the paper towels forming an air tight seal plug about 1.5" into the port , this is easily removed once the port works done and the wax tends to trap any tiny bits or metallic chips the shop vacuum may miss or
http://www.homedepot.com/Tools-Hardware ... ogId=10053

fails to grab
(beeswax can commonly be found in toilet seal rings cheaply at hardware stores)

place several magnets near each port, to trap iron dust and have a buddy use your shop vacuum to remove chips as they are cut, while you use the die grinder after carefully marking the heads first with machinist dye, take your time, and clean up carefully


once the head ports entrances are cut/blended use the shop vac to clean anything missed and only then remove the wax plugs and paper plugs, and residual wax melts on first start-up and will be washed out quickly
last remove the magnets and lifter galley protection, and re-install the valve train,etc.

BTW everyone eventually screws up some part made of aluminum, and TIG welding and re machining will fix almost any aluminum part, especially cylinder heads where heat and pressure make using epoxy less than ideal in many cases, but for minor intake manifold runner, and plenum repairs you usually have a second option, with welding you take a chance of warping the intake casting, but with a paste made from two part epoxy, 75% epoxy and 25% aluminum powder mix, the mix makes a very durable port wall filler paste,vaguely resembling a silver bondo paste but far more durable..
this paste is very useful when correcting intake runner porting mistakes as the paste once cured is machinable to some extent almost like the original aluminum, just be very sure the surface you use the epoxy on is very clean and a thin wet bond coat of epoxy gel a few thousands thick used just before using the paste on the surface before applying the aluminum mixed epoxy filler helps bond the mixed paste


one other very frequent use for my shop vac is to collect metallic debris,Obviously having the heads off the car and easily accessed helps, when I port cylinder heads, I usually tape some 1.5" plastic conduit to the shop vac suction hose, then tape the tip of the conduit to the opposite end of the port Im working on with duct tape, (obviously youll remove the valves before porting or port matching heads)
you can place the suction hose extension, in the far end of a port and duct tape it in place temporarily, and then use a die grinder to clean up the port and the shop vac will collect the vast majority of the metallic chips , having the shop vacuum constantly sucking the metallic debris out of the port also tends to cool the cutting burr, and slow the flutes on the burr from clogging with crud, but youll still want to dip the cutting burr in a mix of marvel mystery oil and WD40 every few seconds to prevent aluminum chips from clogging the burrs cutting flutes or the burr heating up


http://www.summitracing.com/parts/PRO-66483/

a decent cylinder head stand helps

read these threads
viewtopic.php?f=52&t=462&st=0&sk=t&sd=a&hilit=porting+help

viewtopic.php?f=52&t=3143&p=8387&hilit=porting+help#p8387

viewtopic.php?f=55&t=2773&p=7802&hilit=+porting+help#p7802

viewtopic.php?f=52&t=2630&p=6788&hilit=+porting+help#p6788

viewtopic.php?f=44&t=366&p=448#p448

viewtopic.php?f=27&t=1831&p=4763&hilit=+porting+help#p4763

http://www.devcon.com/products/products ... milyID=107

viewtopic.php?f=44&t=6204&p=19420&hilit=cold+start+injector#p19420

http://www.ramracing.us/products.htm

http://www.jamestowndistributors.com/us ... 8&type=pla

viewtopic.php?f=54&t=120&p=867&hilit=+magnets#p867

http://www.superchevy.com/how-to/corp-0 ... epair.html

viewtopic.php?f=52&t=462&p=7566&hilit=porting+burr#p7566

http://www.harborfreight.com/1-4-quarte ... 93389.html

viewtopic.php?f=50&t=3422&p=9065&hilit=abrasives#p9065

viewtopic.php?f=52&t=462&st=0&sk=t&sd=a&hilit=porting+help

be aware that the lower runner gasket is not interchangeable between the drivers and pass sides of the engine on a tpi and if installed incorrectly that results in hard starts a big vacuum leak and an engine that won,t idle