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Spaz
02-13-2013, 10:19 PM
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

Spaz
02-13-2013, 10:20 PM
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

Spaz
02-13-2013, 10:20 PM
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.

Spaz
02-14-2013, 12:25 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?

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.

Spaz
02-17-2013, 06:20 PM
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 ;)

Spaz
03-04-2013, 06:30 PM
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