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 [Picture Journal] Polishing the Intake Manifold 
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Post Re: [Picture Journal] Polishing the Intake Manifold
I would like to port match it to the heads, but one step at a time.

*edit* I think I make this process a lot longer than it should be. If I dedicated a few full days without interruption it probably would be done in a decent amount of time.

The trick is to have the right tools available. Most of the time spent is using tools that don't get the job done efficiently. Once you find that magic tool the job is a lot faster.

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December 04 2012, 7:30 PM
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Post Re: [Picture Journal] Polishing the Intake Manifold
long you say? I started and after a week of doing it, it ended up powdercoated! haha nice work man!


December 04 2012, 9:03 PM
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Post Re: [Picture Journal] Polishing the Intake Manifold
First post - February
Current post - December

Progress: Nowhere near done.

Long, I say!

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December 04 2012, 9:49 PM
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The Mayan's say there's not much time left. Better hurry up. :lol:

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December 04 2012, 11:52 PM
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Post Re: [Picture Journal] Polishing the Intake Manifold
did a little more grinding.
Image
Image
Image

Think that took about 2 hours.

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Last edited by SuperK on September 24 2014, 6:19 PM, edited 1 time in total.



December 09 2012, 3:34 AM
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You're a sculptor. Nice work.

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December 10 2012, 1:10 AM
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Post Re: [Picture Journal] Polishing the Intake Manifold
Did you grind out all that flashing or cut it out. I've found you can take out large chunks of aluminum pretty quick by drilling into it with a large sized drill bit. (start with small bit then get progressively bigger.) Or if you have a pneumatic body saw that could help too rather than grinding away at that stuff.


January 03 2013, 7:56 PM
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Post Re: [Picture Journal] Polishing the Intake Manifold
Haven't given up (yet) on this thing.

At one point I got discouraged so I started polishing just a corner so I wouldn't get discouraged.

Image

Image

That gave me a little more motivation so I kept working at it.

Image




I then focused on the neck of the intake:

Before:
Image


After:

Image


Comparing it to the Millennia intake, I am beginning to be pleased with my progress:
Image

Image

Seems like the intake throat of the Millenia manifold doesn't have a knife edged divider like the imported Xedos curve neck manifold.

Image

Image

Easy to identify by the "casting ridge" that's on main plenum on the Xedos manifold that's not on the Millennia one.

Then wanted to smooth out the top cap:

Image

Image

I think I will keep thinning that plate out , see if I can get a little more clearance out of it.

Also shaved off the nub:

Image



"Clanky" has since this work taken all my free time. It's going to be many weeks before I can start back on this.

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Last edited by SuperK on September 24 2014, 6:20 PM, edited 1 time in total.



November 03 2013, 6:09 PM
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Post Re: [Picture Journal] Polishing the Intake Manifold
Looking good! keep up the good work.

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November 04 2013, 12:29 PM
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Post Re: [Picture Journal] Polishing the Intake Manifold
Corded Power Drill
http://www.sears.com/craftsman-1-2-in-c ... ckType=G10
I use a Craftsman because it had a trigger lock and a handle. Both features are very useful. Any power drill will do.

Power Drill Accessories


Corded Rotary Tool
http://www.dremel.com/en-us/Tools/Pages ... t1qLHko6TM
I use dremel brand w/variable speed. Any brand will do.

Rotary Tool Accessories


Metal File Set
http://www.sears.com/nicholson-5pc-hand ... ockType=G1
I purchased the above on sale. Find a set with:
    Handles
    Mill Bastard
    Round Mill Bastard
    Half Round Mill Bastard
    Both Rasp and Files


Sandpaper
http://www.magnate.net/ProductDetails.a ... Code=PG169
Silicon Carbide Wet/Dry, in bulk
List of grit based on how tenacious you are:
    100
    200
    400
    800
    1000
    1500
    2000
    2500

-------------------------------------------------------

I break up the costs in two categories:
Invested and disposed currency.

Then invested currency will be the cost of reusable tools: Power tools, mandrels, files.
The disposed currency are the cost of materials that are not reusable: Sanding bands and sandpaper.
Although you need to budget both categories before committing to hours upon grueling hours of monotonous, disparaging work, only the disposed currency is the actual cash value you're placing in your intake manifold... plus dozens of wasted labor hours you could have spent working overtime and making thousands of extra dollars.

There are many other tools and methods to polishing. I chose this particular route because I felt in control of how much material I was removing, and it offered a good deal of precision.
But be warned... it is a long... long, boring, long, boring, long, long, boring, long, boring task.
I also recommend a laptop connected to multiple series streaming sites. Just sit, sand and stare. It's a great way to get caught up on series that your friends are talking about, but you can't justify sitting down and dedicating time to watch that particular show.
I can now talk to my friends about Trueblood (and how terrible it is) and have successfully not wasted any productive time watching it.

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January 20 2014, 3:22 PM
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Post Re: [Picture Journal] Polishing the Intake Manifold
It's getting there :2thumbsup:

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January 20 2014, 6:05 PM
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