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/a...1-13124954.jpg


First thing I did was take off all the nuts and bolts and double sided studs
http://i918.photobucket.com/albums/a...1-14191420.jpg

From there I cut off the brackets for the manifold cover
http://i918.photobucket.com/albums/a...1-14193528.jpg


Then using my air grinder grinded down the rest
http://i918.photobucket.com/albums/a...1-14195656.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/a...1-18171854.jpg


And I marked off my cut lines and then began to cut
http://i918.photobucket.com/albums/a...1-18182315.jpg

and Bam it's done!
http://i918.photobucket.com/albums/a...1-18182651.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/a...1-18183434.jpg


and began with 60 grit flap discs
http://i918.photobucket.com/albums/a...1-19083527.jpg

http://i918.photobucket.com/albums/a...1-20193443.jpg


and here is a rough finished in 80 cover
http://i918.photobucket.com/albums/a...1-20194426.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/a...1-20194831.jpg

http://i918.photobucket.com/albums/a...1-20194957.jpg

http://i918.photobucket.com/albums/a...1-20194845.jpg


And after some sanding
http://i918.photobucket.com/albums/a...1-20200910.jpg

http://i918.photobucket.com/albums/a...1-20201851.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/a...1-25205612.jpg

http://i918.photobucket.com/albums/a...1-25194133.jpg

http://i918.photobucket.com/albums/a...1-25200645.jpg


Then started sanding it back down again
http://i918.photobucket.com/albums/a...1-25203323.jpg

Then used a 6" extension to start cleaning the insides
http://i918.photobucket.com/albums/a...1-22193625.jpg

Here's some progress
http://i918.photobucket.com/albums/a...1-25220805.jpg

http://i918.photobucket.com/albums/a...1-25220816.jpg

80 grit
http://i918.photobucket.com/albums/a...1-25220755.jpg


And for a teaser I tried 120 grit
http://i918.photobucket.com/albums/a...1-25222926.jpg


Looks at the difference!
http://i918.photobucket.com/albums/a...1-25222940.jpg

Now I focused on the throttle body entrance... It has shitty castings and lots of obstructions
http://i918.photobucket.com/albums/a...1-20200759.jpg


Especially this big IACV lump
http://i918.photobucket.com/albums/a...1-25212348.jpg

So I started sanding and cutting it down
http://i918.photobucket.com/albums/a...1-25212359.jpg


And now look at this beautiful passageway! Not finished yet but looking damn good
http://i918.photobucket.com/albums/a...1-25214947.jpg

Worked on the outside some more

Cut this tab off
http://i918.photobucket.com/albums/a...1-26173530.jpg


And got rid of the piece on the top
http://i918.photobucket.com/albums/a...1-26173522.jpg


Then got out the drill and started making holes
http://i918.photobucket.com/albums/a...1-26173514.jpg


and smoothed it out for the most part
http://i918.photobucket.com/albums/a...1-26182543.jpg



So I started cleaning out the front of the runners tonight.
Here is what I started with
http://i918.photobucket.com/albums/a...1-27190314.jpg

http://i918.photobucket.com/albums/a...1-27190505.jpg

and after some sanding
http://i918.photobucket.com/albums/a...1-27190451.jpg

http://i918.photobucket.com/albums/a...1-27190406.jpg



and a comparison shot
http://i918.photobucket.com/albums/a...1-27190525.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/a...1-29184415.jpg

Here is what I was working with
http://i918.photobucket.com/albums/a...1-29184514.jpg


Wasn't to bad.. but room for improvement
http://i918.photobucket.com/albums/a...1-29184504.jpg


So I started grinding out the runners
http://i918.photobucket.com/albums/a...1-29190819.jpg

Then smoothed them back down
http://i918.photobucket.com/albums/a...1-29192539.jpg


Then evened them out and sanded them smooth and put the gasket back on to check it out
http://i918.photobucket.com/albums/a...1-29192640.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/a...ps9abe7f56.jpg

Then started smoothing everything with 80 grit and then 120
http://i918.photobucket.com/albums/a...psa980ac66.jpg

http://i918.photobucket.com/albums/a...psd964152a.jpg

here is 120
http://i918.photobucket.com/albums/a...ps63ec2b3b.jpg

air will flow nicely into this beast!
http://i918.photobucket.com/albums/a...pseb0a3893.jpg

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?

Damn if that's not the sexiest thing ever. I would do my best to make love to that thing.

Quote:

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Originally Posted by boosted_teg

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?

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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/a...psf141e72c.jpg

http://i918.photobucket.com/albums/a...ps57bcfe59.jpg

getting closer
http://i918.photobucket.com/albums/a...psbde23127.jpg

and then
http://i918.photobucket.com/albums/a...ps45f2f73e.jpg


Also started cleaning down the runners
http://i918.photobucket.com/albums/a...psdf589094.jpg


And cleaned the top half so the welding will be easier
http://i918.photobucket.com/albums/a...ps33fea75d.jpg

can't get tighter than this
http://i918.photobucket.com/albums/a...ps8a97b293.jpg


Now just to weld it
http://i918.photobucket.com/albums/a...ps14d0c9e9.jpg

ill just send my manifold down to you to port out ;)

That looks nasty!! i would like to see a flow chart done also.

I can't wait until this is done! Need this soon so I can paint and install it ;)

http://i918.photobucket.com/albums/a...ps9065b27c.jpg


Almost there!

Ill be doing this to mine also! Good job bro looks amazing

wow beautiful work im on the hunt for some extra RBC manifold so i can attempt to do this myself!!!!! awesome write up.......

Quote:

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Originally Posted by echo3gulf

wow beautiful work im on the hunt for some extra RBC manifold so i can attempt to do this myself!!!!! awesome write up.......

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:wavey: Hey buddy!

Hey man whats good its been forever since ive been on here!!!!!

Here's my ported n polished IM all finished, by the ine and only [MENTION=28]Spaz[/MENTION]!

http://img.tapatalk.com/d/13/08/01/2u2a8ygu.jpg

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

Quote:

---

Originally Posted by echo3gulf

Hey man whats good its been forever since ive been on here!!!!!

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Same stuff, boostin bitches and getting numbers. Lmao. Whats new with you?

Turned out nice