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Thread: DIY: Shaving and Porting Intake Manifolds

  1. #1
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    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.



    First thing I did was take off all the nuts and bolts and double sided studs


    From there I cut off the brackets for the manifold cover



    Then using my air grinder grinded down the rest



    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



    And I marked off my cut lines and then began to cut


    and Bam it's done!



    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



    and began with 60 grit flap discs





    and here is a rough finished in 80 cover
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  4. #2
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    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...







    And after some sanding





    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







    Then started sanding it back down again


    Then used a 6" extension to start cleaning the insides


    Here's some progress




    80 grit



    And for a teaser I tried 120 grit



    Looks at the difference!
    Available now are SPAZ APPROVED decals!!! Available in multiple colors!


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  5. #3
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    Now I focused on the throttle body entrance... It has shitty castings and lots of obstructions



    Especially this big IACV lump


    So I started sanding and cutting it down



    And now look at this beautiful passageway! Not finished yet but looking damn good


    Worked on the outside some more

    Cut this tab off



    And got rid of the piece on the top



    Then got out the drill and started making holes



    and smoothed it out for the most part




    So I started cleaning out the front of the runners tonight.
    Here is what I started with




    and after some sanding






    and a comparison shot


    Ok so I finished the final porting today.

    I installed the gasket and took a marker and traced out the difference


    Here is what I was working with



    Wasn't to bad.. but room for improvement



    So I started grinding out the runners


    Then smoothed them back down



    Then evened them out and sanded them smooth and put the gasket back on to check it out


    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


    Then started smoothing everything with 80 grit and then 120




    here is 120


    air will flow nicely into this beast!
    Available now are SPAZ APPROVED decals!!! Available in multiple colors!


    Need parts?! Check out our eShop and let me know! We can help you out!
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  6. #4
    Premium Member boosted_teg's Avatar
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    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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  7. #5
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    DIY: Shaving and Porting Intake Manifolds

    Damn if that's not the sexiest thing ever. I would do my best to make love to that thing.
    Tire slayer
    Breaking everything since 2011

  8. #6
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    Quote Originally Posted by boosted_teg View Post
    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.
    Available now are SPAZ APPROVED decals!!! Available in multiple colors!


    Need parts?! Check out our eShop and let me know! We can help you out!
    http://boostedk20.com/eshop/

  9. #7
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    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




    getting closer


    and then



    Also started cleaning down the runners



    And cleaned the top half so the welding will be easier


    can't get tighter than this



    Now just to weld it
    Available now are SPAZ APPROVED decals!!! Available in multiple colors!


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  10. #8
    Premium Member boosted_teg's Avatar
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    ill just send my manifold down to you to port out
    2001 Boosted Built k20a2 Billet BB 6766BB

    2013=579whp 406trq @ 24 psi c16
    10.87@137mph

    2014= 510whp 370trq @ 18psi pump gas


    2015= 7xx @ 30psi??

  11. #9
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    That looks nasty!! i would like to see a flow chart done also.

  12. #10
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    Re: DIY: Shaving and Porting Intake Manifolds

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

    "As I lay rubber down to street, I pray for traction I can keep. But if I spin and begin to slide, please oh please protect my ride."

    One-off SRT Top Mount Manifold - GT3076R
    My Ruckus Build

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