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View Full Version : DIY: Shaving RBC intake manifold



Spaz
03-27-2012, 09:54 PM
I'm not done yet but a member sent me his RBC and asked if I could shave it for him. Of course I was up for that challenge :thumbsup:

Here is what I started with
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-03-25153950.jpg


my weapons of choice, cut off wheel, grinder, sander, 80 grit disc

started with small things like these
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-03-25154141.jpg

then cut down
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-03-25154954.jpg

then sanded smooth
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-03-25160237.jpg

then also did a bunch of misc ones
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-03-25154150.jpg

smooth
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-03-25160243.jpg


the big one I'm working on though is eliminated the sensor ports. Started worth:
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-03-25154157.jpg

started cutting
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-03-25170837.jpg

kept cutting
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-03-25173849.jpg

smoothed it with sand paper to see how it's coming
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-03-25183534.jpg


I'm waiting to weld up the holes but here is my so far end result
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-03-25182057.jpg



I really enjoyed this manifold so if anyone else wants one shaved let me know :thumbsup:

Si Speed 317
03-28-2012, 11:57 AM
Nice, looks awesome! Will you cut out the 'bridges' between the 1-2 and 3-4 runners? Or leave those in? And what color will it end up being?

Spaz
03-28-2012, 09:46 PM
never thought about cutting the bridges..........

it's going to be polished to a blingtastic shine

boosted_teg
03-29-2012, 01:51 AM
thats one thing i wish i wouldve done, cut the webbing between the runners. Ill never polish another one again hhaha so much maintenance ;)

AxelTaylor
03-29-2012, 11:50 PM
Exactly what I did to mine. Good job zack!

BoostedK20
04-01-2012, 01:39 PM
Great DIY Spaz! Repped.

Spaz
04-01-2012, 05:37 PM
Ok so more updates on the RBC

I put my throttle body on to compare the edges
http://i918.photobucket.com/albums/ad22/typespaz/2012-04-01135324.jpg

Marked it with a marker
http://i918.photobucket.com/albums/ad22/typespaz/2012-04-01135412.jpg

and cut it down
http://i918.photobucket.com/albums/ad22/typespaz/2012-04-01135837.jpg


First I hit as much as I could with an 80grit disc wheel
http://i918.photobucket.com/albums/ad22/typespaz/2012-04-01144818.jpg

http://i918.photobucket.com/albums/ad22/typespaz/2012-04-01144831.jpg


Then to test to see how it would work I did a small section in flap wheels
http://i918.photobucket.com/albums/ad22/typespaz/2012-04-01144919.jpg


It was looking good
Then I used flap wheels 60, 80, 120
http://i918.photobucket.com/albums/ad22/typespaz/2012-04-01145325.jpg


obviously I am far from done but taking a break for now.
http://i918.photobucket.com/albums/ad22/typespaz/2012-04-01161900.jpg

Spoolin_VTEC
04-03-2012, 01:13 PM
Wait, one of the ports you removed is a vital vacuum source from the IM. Now what?

Spaz
04-12-2012, 05:37 PM
So went out to the garage for an hour and kept shaving on this manifold...

decided I didn't want this here
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-04-11215817.jpg

so I cut it off
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-04-11220103.jpg

and smoothed it out
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-04-11223126.jpg


also cut out this area so we can put the vacuum hose barbs
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-04-11223135.jpg


and sanded down the welds (need to redo two of them though... )
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-04-11223153.jpg

http://i918.photobucket.com/albums/ad22/typespaz/RBC%20shave/2012-04-11223200.jpg

AxelTaylor
04-12-2012, 09:43 PM
Decide if you are going to cut out the webbing or not?

Spaz
04-12-2012, 10:23 PM
Decide if you are going to cut out the webbing or not?


yeah I'm working on that next

Si Speed 317
04-15-2012, 07:17 PM
Vacuum port on the back is a great idea. Talk about hidden! How's it looking now?

Spaz
04-16-2012, 10:16 PM
^I will upload photos tomorrow... I'm having pitting issues that are pissing me off lol

PetefromtheStreets
04-18-2012, 10:32 PM
Things looking good man. I like the "I didnt want this here" "so I cut it off". LOL

Si Speed 317
08-01-2013, 12:16 AM
Well, here are pics before I finally install this mamajama!
http://img.tapatalk.com/d/13/08/01/2u2a8ygu.jpg

http://img.tapatalk.com/d/13/08/01/usydu8u6.jpg

Tape tape tape! Tape tape tape! Tape your mani. Tape your mani!!
http://img.tapatalk.com/d/13/08/01/ny7yhyqu.jpg

Amazing job by the one and only Spaz. Thank you again, brother. I am very excited for this!

PetefromtheStreets
08-01-2013, 04:18 PM
Well, here are pics before I finally install this mamajama!
http://img.tapatalk.com/d/13/08/01/2u2a8ygu.jpg

http://img.tapatalk.com/d/13/08/01/usydu8u6.jpg

Tape tape tape! Tape tape tape! Tape your mani. Tape your mani!!
http://img.tapatalk.com/d/13/08/01/ny7yhyqu.jpg

Amazing job by the one and only Spaz. Thank you again, brother. I am very excited for this!

Big ass gorilla hands... Lol

s4 IG-petefromthestreets

Spaz
08-02-2013, 09:52 AM
It was fun getting to do a new project.

ksboi
08-02-2013, 02:25 PM
Why taping it off?

Si Speed 317
09-06-2013, 02:28 AM
Big ass gorilla hands... Lol

s4 IG-petefromthestreets
That's what I said! He works at body shops, so I guess it adds up lol.

It was fun getting to do a new project.
It was an insane result man. How did those bits do btw? I never got to ask.

Why taping it off?
We were painting it, don't want to get anything on any flange mating surfaces

echo3gulf
11-13-2013, 08:34 PM
When you shaved down the spot for the map how did you put it back on? Thats and all the grounds where d they go if you shaved off all of the mounting spots?

Spaz
11-13-2013, 08:38 PM
When you shaved down the spot for the map how did you put it back on? Thats and all the grounds where d they go if you shaved off all of the mounting spots?

The holes I filled in with an aluminum welder then grinder back down. As far as grounds there is only one in the harness by the valve cover not on the manifold and you can easily relocate it when you tuck the harness.

Sent from my SCH-I545 using Tapatalk

Si Speed 317
11-13-2013, 09:09 PM
http://img.tapatalk.com/d/13/11/14/5eryzy8y.jpg

There you go sir

Spaz
11-13-2013, 09:10 PM
Damn I did good on that ;)

Sent from my SCH-I545 using Tapatalk

echo3gulf
11-14-2013, 02:21 AM
Okay so just tap a hole in the bottom and just put a hose on it. Idk what all those other hoses sre tho.

Spaz
11-14-2013, 08:12 AM
Okay so just tap a hole in the bottom and just put a hose on it. Idk what all those other hoses sre tho.

He's boosted.... One for the FPR, one for waste gate, one for boost solenoid, one for map sensor and one for brake booster. I even have another one for a direct line to my boost gauge

Sent from my SCH-I545 using Tapatalk

echo3gulf
11-15-2013, 01:44 AM
ya makes sense I have a block off plate so everything just plugs into it. What dermal attachment did you use to shave the space between the runners???

Si Speed 317
11-15-2013, 02:56 AM
ya makes sense I have a block off plate so everything just plugs into it. What dermal attachment did you use to shave the space between the runners???

You can drill a bunch of small holes side by side, and then go over them again with a bigger bit. Spaz would know what to do better though. That's just my .02 with a 2am state of mind.

Also, are you going to port this yourself? Because you can't use a dremel for that

echo3gulf
11-15-2013, 07:10 AM
yes I am, I understand that I already got me some sand paper the only thing is, is that I have to order me some flapper disks cause every hardware store around doesn't carry them.......

Spaz
11-15-2013, 08:20 AM
Cutting out the runners sucks lol I used a lot of drill bits. I didn't start with small one though I just went for it with big boys lol

Sent from my SCH-I545 using Tapatalk

Si Speed 317
11-15-2013, 11:32 AM
yes I am, I understand that I already got me some sand paper the only thing is, is that I have to order me some flapper disks cause every hardware store around doesn't carry them.......

Home depot, or walmart. But they'll likely come in packs.

aLmk
11-15-2013, 01:17 PM
He's boosted.... One for the FPR, one for waste gate, one for boost solenoid, one for map sensor and one for brake booster. I even have another one for a direct line to my boost gauge

Sent from my SCH-I545 using Tapatalk
I hope the one for his boost solenoid has a check valve in it. The wastegate is not supposed to see vac, it can damaged the diaphragm over time.

Si Speed 317
11-15-2013, 02:48 PM
I hope the one for his boost solenoid has a check valve in it. The wastegate is not supposed to see vac, it can damaged the diaphragm over time.

No boost controller seeing vacuum over here! He spoke for me. He wasn't right tho. Lol. Thank you for clarifying.

I have my bov, fpr, brake booster, and boost gauge tapped to my IM.

Spaz
11-15-2013, 03:22 PM
Sorry was typing fast at work just listed some things lol

Sent from my SCH-I545 using Tapatalk

echo3gulf
11-15-2013, 05:33 PM
I don't have a boost solenoid hooked up yet and I know its not supposed to hook up to that, I'm just running a manual boost controller for now. I was just using it as a reference.

aLmk
11-16-2013, 10:48 AM
All good, just wanted to make sure your diaphragm doesn't tear.

asdf
02-27-2014, 11:53 AM
http://img.tapatalk.com/d/13/11/14/5eryzy8y.jpg

There you go sir

Do you happen to remember what size fittings you used? Specifically for the brake booster.

ryaano18
02-27-2014, 01:31 PM
Do you happen to remember what size fittings you used? Specifically for the brake booster.
it looks like 1/4 npt to 3/8 barb
like this
http://www.jegs.com/i/Derale/259/98100/10002/-1

Spaz
02-27-2014, 01:58 PM
^correct. All my taps were 1/4" NPT. Then just used a 1/4 to 3/8 fitting

asdf
02-27-2014, 03:20 PM
it looks like 1/4 npt to 3/8 barb
like this
http://www.jegs.com/i/Derale/259/98100/10002/-1


^correct. All my taps were 1/4" NPT. Then just used a 1/4 to 3/8 fitting

Awesome thanks guys :thumb:

asdf
03-16-2014, 02:18 PM
Ok noob question...I was looking up what size drill bit to use for the 1/4" NPT tap, is 7/16" the correct drill bit to use?
http://www.bigblockdart.com/techpages/TapDrillChart.shtml
http://www.carbidedepot.com/formulas-tap-pipe.htm confused by the "pipe reamer" part lol

BoostedK20
12-28-2017, 11:31 AM
RBC porting is such common place now, although many other IM's are available aftermarket (i.e. Skunk2, K-Tuned, Gato, Pro-Jay, etc. Miss this!

Si Speed 317
01-07-2018, 11:22 AM
I'll be working on the car again soon. Going to need a revamping for sure! Although there are some badass IM setups out now (several years later) I plan on keeping this P&P Spaztastic IM :pimp::spaz: