View Full Version : DIY: Shaving and Porting Intake Manifolds
So here is my latest project for a customer. I am not finished yet but I will be updating this thread as I go.
Tools Used:
Grinder
Cut Off Wheels
Flap Discs
Air Tools
Drill / Bits
Vice
Sockets
Ok so lets begin. Here is what I am starting with. It is an RBC Intake Manifold off of the Honda Civic SI. I am going to be doing a full shave on the outside and inside.
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-13124954.jpg
First thing I did was take off all the nuts and bolts and double sided studs
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-14191420.jpg
From there I cut off the brackets for the manifold cover
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-14193528.jpg
Then using my air grinder grinded down the rest
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-14195656.jpg
I've put the outside on hold but I will be cutting out the webbing and some other misc pieces later on.
So now to the fun part!
Lets cut this manifold open. To do so here is what I used
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-18171854.jpg
And I marked off my cut lines and then began to cut
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-18182315.jpg
and Bam it's done!
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-18182651.jpg
So to start my journey I began with the outside cover. There is so much casting fail... so rough. So I put it in the vice
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-18183434.jpg
and began with 60 grit flap discs
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-19083527.jpg
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-20193443.jpg
and here is a rough finished in 80 cover
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-20194426.jpg
Now onto the inside... this part is scary so I am taking my sweet time. But damn I got the hang of it quick and really starting to make some progress!
First I started sanding everything with 60 grit like the cover...you really start seeing the shit castings...
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-20194831.jpg
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-20194957.jpg
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-20194845.jpg
And after some sanding
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-20200910.jpg
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-20201851.jpg
Now onto the tough part... Using Carbine Bits for Aluminum I started sculpting and shaping. Lots of high spots and flat spots.. plenty of room for improvement
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-25205612.jpg
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-25194133.jpg
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-25200645.jpg
Then started sanding it back down again
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-25203323.jpg
Then used a 6" extension to start cleaning the insides
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-22193625.jpg
Here's some progress
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-25220805.jpg
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-25220816.jpg
80 grit
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-25220755.jpg
And for a teaser I tried 120 grit
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-25222926.jpg
Looks at the difference!
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-25222940.jpg
Now I focused on the throttle body entrance... It has shitty castings and lots of obstructions
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-20200759.jpg
Especially this big IACV lump
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-25212348.jpg
So I started sanding and cutting it down
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-25212359.jpg
And now look at this beautiful passageway! Not finished yet but looking damn good
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-25214947.jpg
Worked on the outside some more
Cut this tab off
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-26173530.jpg
And got rid of the piece on the top
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-26173522.jpg
Then got out the drill and started making holes
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-26173514.jpg
and smoothed it out for the most part
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-26182543.jpg
So I started cleaning out the front of the runners tonight.
Here is what I started with
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-27190314.jpg
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-27190505.jpg
and after some sanding
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-27190451.jpg
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-27190406.jpg
and a comparison shot
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-27190525.jpg
Ok so I finished the final porting today.
I installed the gasket and took a marker and traced out the difference
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-29184415.jpg
Here is what I was working with
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-29184514.jpg
Wasn't to bad.. but room for improvement
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-29184504.jpg
So I started grinding out the runners
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-29190819.jpg
Then smoothed them back down
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-29192539.jpg
Then evened them out and sanded them smooth and put the gasket back on to check it out
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-01-29192640.jpg
So finally got back to the RBC I've been working on...
found a high spot I didn't like so kept grinding it down
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-10182935_zps9abe7f56.jpg
Then started smoothing everything with 80 grit and then 120
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-10194555_zpsa980ac66.jpg
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-10194604_zpsd964152a.jpg
here is 120
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-10192212_zps63ec2b3b.jpg
air will flow nicely into this beast!
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-10192157_zpseb0a3893.jpg
boosted_teg
02-14-2013, 12:19 AM
thanks for write up.
i might have to do this to mine in another month or so.
did u use any sort of lubricant to keep the bits from gumming up?
PetefromtheStreets
02-14-2013, 12:24 AM
Damn if that's not the sexiest thing ever. I would do my best to make love to that thing.
thanks for write up.
i might have to do this to mine in another month or so.
did u use any sort of lubricant to keep the bits from gumming up?
No.. just a wire brush. My main bit I used is specifically for aluminum and it is very corse teeth so it doesn't gum up easily.
Alright almost finished! Just need to weld it up and then clean the welds
So I convinced my customer to relocate map so I started cutting the manifold down :)
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-17125923_zpsf141e72c.jpg
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-17125931_zps57bcfe59.jpg
getting closer
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-17135707_zpsbde23127.jpg
and then
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-17132720_zps45f2f73e.jpg
Also started cleaning down the runners
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-17135635_zpsdf589094.jpg
And cleaned the top half so the welding will be easier
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-17143304_zps33fea75d.jpg
can't get tighter than this
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-17143334_zps8a97b293.jpg
Now just to weld it
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-02-17143417_zps14d0c9e9.jpg
boosted_teg
02-17-2013, 07:56 PM
ill just send my manifold down to you to port out ;)
ksboi
02-17-2013, 10:38 PM
That looks nasty!! i would like to see a flow chart done also.
Si Speed 317
02-25-2013, 11:22 AM
I can't wait until this is done! Need this soon so I can paint and install it ;)
http://i918.photobucket.com/albums/ad22/typespaz/RBC%20Project%20Dan/2013-03-04160615_zps9065b27c.jpg
Almost there!
1SLOWFG2
03-04-2013, 08:45 PM
Ill be doing this to mine also! Good job bro looks amazing
echo3gulf
10-06-2013, 11:35 PM
wow beautiful work im on the hunt for some extra RBC manifold so i can attempt to do this myself!!!!! awesome write up.......
Si Speed 317
10-06-2013, 11:36 PM
wow beautiful work im on the hunt for some extra RBC manifold so i can attempt to do this myself!!!!! awesome write up.......
:wavey: Hey buddy!
echo3gulf
10-07-2013, 12:36 AM
Hey man whats good its been forever since ive been on here!!!!!
Si Speed 317
10-07-2013, 01:07 PM
Here's my ported n polished IM all finished, by the ine and only Spaz!
http://img.tapatalk.com/d/13/08/01/2u2a8ygu.jpg
http://img.tapatalk.com/d/13/08/01/usydu8u6.jpg
Hey man whats good its been forever since ive been on here!!!!!
Same stuff, boostin bitches and getting numbers. Lmao. Whats new with you?
echo3gulf
10-07-2013, 02:06 PM
Turned out nice
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