Follow my port and polish project

[DougsfastZ]

These are shots of the 4 red dots where I drilled alignment holes. These red dots were actually too high and missed the gasket. So I moved the holes down towards the valley in the crevice between the intake bolt and the coolant passage. That brought the hole low enough to go through the gasket. I liked this location since it was on a blank spot on the head and I was able to get the drill at the right angle. I used 4 nails, 1/8" in diameter, with the tips cut off, as alignment dowels. All I did was drill through the intake, through the gasket, and maybe an 1/8" into the head.









Here is the shot of the drill bit with electrical tape being used as a depth gauge.



Here is a shot of the intake, with the correct holes drilled, and the nails being used as alignment pins.





These are pics of the scribe marks I made. All I did was pull the intake off carefully to not move the gasket, then scribed the marks on the heads using a dental tool. I didn't have any machinist die, so I use a very large permanent marker. Make sure you paint the head ports before installing the gasket and intake.





Continued......

[DougsfastZ]

Then I painted the runner exits on the intake with the marker. I took the gasket off and aligned it onto the intake using the nails. Here are the scribe marks.





Here are the heads ported to the scribe lines. I only ported down about an inch into the port. I only used the carbide burs and 80 grit sanding rolls.







Here is a shot of me porting while my brother held a powerful shop vac right above the port to help keep the shavings to a minimum. Notice I kept the valve covers on to keep metal from getting into the top of the heads.



Here are shots of the ported head runners with the gasket in place. Notice the nails lining everything up.









Continued

[DougsfastZ]

Here are shots of the lower intake ported. I only ported and blended about 2 inches up the runner. I left it at 80 grit.







The ports matched up to the gasket. Notice I did not port the floor, just deburred it.





Here is a shot of the intake bolted to the motor. I used a dental tool to feel down the runners. The transition feels nice and smooth. The floor of the runner drops a little bit into the head, but from what I understand, there is not much velocity on the floor.




Another thing I did was cut and old factory 02 sensor to the threads since I run a wide band now. The factory sensor is pretty large and can't help flow to the turbo.



Got about half of the motor put back together, it should be up and running in the next few days.

I did keep track of most of the before and after measurements using my digital caliper. I'll post those numbers in the next few days.

Unfortunately my local 1/4 mile track is closed till at least October, so I won't have any numbers till then. If I do feel a SOTP difference, I'll post about it.

Just FYI, I loosely calculated the work I've done about about 40 hours.

Thanks for all the help guys!

[DonWG]

Dang good work. I am impressed. Can't wait to see how it works out.

[UNGN]

On the Upper intake, I welded in a piece of AL sheet to make a $3 Hemco.



I left the EGR tower in the lower in place, but turned the Upper manifold portion of the tower into a nice semi sphere, instead of just cutting it off (not shown in the above picture).

My car went 118.3 with an otherwise 100% stock longblock with 36# bluetops, so I don't think it was hurting anything.

[DougsfastZ]

I've seen you post about that before. I've been running a RJC power plate since I bought the car. From the data I've seen, the plate works better then a Hemco.

Thanks for the tip.

[TURBOPOWERED68]

great write up Dude.

[scojack_2001]

Nice write up. I got the 11-second stock turbo timeslip by running 26° of timing and 26psi. Stock untouched intake, only a ported compressor housing on the turbo, ported IC and plenum, stock TB, and a PP.

I havent been able to get back to that yet.

Hope you get that 11 second timeslip! I know I sure was surprised!

[Sleeper-6]

Nice write up! I vote that we make this a sticky.

[topfuel]

This is one of the best threads I've ever seen, nice job man.

I've gone 12.0 on the stock stuff but can't quite hit 11's.
Maybe doing this portwork will be my ticket to join the elite stock 11 second club!

Thanks for all the detailed description and keep up the good work...
And by the way, put on some safety glasses please...

[charlief1]

Great idea of using nails to line up the intake. Where'd you get the idea?

[GN owner]

Great job! I am interested in the increase in HP once you are done! It's a great way to get the most out of the parts that you already have.

[DougsfastZ]

Originally Posted by GN owner

Great job! I am interested in the increase in HP once you are done! It's a great way to get the most out of the parts that you already have.

Honestly, I'll never know. I've never dynoed the car, and doubt I ever will.

I will however post decreases in track times.

[ULOSE2A6]

Looks Great Doug,

All that work will pay off. I can hardly wait to see it in action on the bridge...haha.

Laterz

Shev

[KILL4PEACEUSMC]

looks like your doing a great job, just wondering why you didnt pull the heads to port them, Ive never seen anyone port heads on an assembled motor before.

[DougsfastZ]

Originally Posted by KILL4PEACEUSMC

looks like your doing a great job, just wondering why you didnt pull the heads to port them, Ive never seen anyone port heads on an assembled motor before.

I get that alot.

My theory is if it isn't broke, don't fix it. The head gaskets are original and have yet to give me any issues.

I'm certain in the future I'll blow one of them trying to go for broke, then I'll port the heads

[KILL4PEACEUSMC]

Ahh yes I call thoses "cornor" heads....."gota new set of heads ready to go sittin over there in the corner" I even have a corner motor too!

[pajo]

great job Doug keep up the good work -- let us know of the differance you've made on the cars drivability and performance ..I did basically the same thing years a go and the first thing a noteced was a much quicker spool up and need for more fuel naturally..Good luck

[1986TR]

any up dates?