How-to DIY Port and Polish - TriStateTuners.com :: Home of Tristate Auto Enthusiast

2point4DSM · 11-30-2005, 10:10 AM

First off, tools make the difference. Having top end and torque is good. With that said, electric is awesome cause it has both. People's opinions may vary. Of course if you could dump $300++ into an air die grinder then I would probably have to reconsider.

Anyway, never port and polish parts on a car if you have to lay on your back to do it. I had a buddy that got a splinter in his eye doing it this way, lol.

Most people would say that port matching is the best bang for the buck.

Keeping the intake side a bit rough and polishing the exhaust side seems to be the ideal way.

MuddyREX · 11-30-2005, 10:12 AM

Did you do some P&P yourself? If so, what parts did you do and how about some before/after pics?

2point4DSM · 11-30-2005, 10:21 AM

Sorry no pics. After an hour or more of porting and polishing my hand would never be stable enough to hold a camera, lol.

But yes, I've done quite a few jobs. I've done several heads, intake and exhaust manifolds, turbine housings, throttle bodies, o2 housings, etc. I started doing it over ten years ago. Lately, I dread the idea of doing anymore jobs. Very time consuming and messy, lol.

It's not hard. Just takes a lot of patience and some background knowledge. For example you can't really go crazy on a head cause you can poke open an coolant passage. At that point you can throw the head aways, lol.

igo4bmx · 11-30-2005, 10:26 AM

http://www.sa-motorsports.com/diyport.shtm

moorefire · 11-30-2005, 10:29 AM

heres a good circle track tech article on porting

http://circletrack.com/techarticles/...5_intake_flow/

2point4DSM · 11-30-2005, 10:33 AM

Also, a lot of people go crazy and take a lot of metal out of exhaust parts. Not really a good idea cause the more mass you take out the sooner it will crack. Of course, if you plan on upgrading to that super duper tubular setup in the near future anyway, then go ahead, go crazy... lol.

S4toSTI · 11-30-2005, 11:10 AM

This is a very cool thread i would really lto see someone who is going to do something like this invite some people over to watch i think pnp is something most car guys are interested in doing but either having the money to buy a second set of heads or other stuff can get expensive. Also those of us without a extra car can not really take vital parts out and send them out for a week. So i think this is something myself and many other would like to learn about. Ok wil so when you doing a "wil teaches pnp to stupid tst kids night?"

MuddyREX · 11-30-2005, 11:12 AM

Seriously, I would never have the balls to try and tackle something like this without seeing it done first.

S4toSTI · 11-30-2005, 11:13 AM

Ok list of tst people attending wil's lesson...(lets put some preassure on him)
1. Muddy
2. Barry
2. pete

sur4die · 11-30-2005, 11:48 AM

i'm in! free (as in beer) modifications are the best!

2point4DSM · 11-30-2005, 12:36 PM

Barry, we need a garage to do this all in. How big did you say your garage is?

I'll show you guys how to draw lines on your manifolds, and turbine housings, etc and it'll be up to you to stay in the lines. Don't worry though it'll take quite a bit of effort to mess up, lol.

S4toSTI · 11-30-2005, 12:41 PM

Quote:

Originally Posted by 2point4DSM

Barry, we need a garage to do this all in. How big did you say your garage is?

I'll show you guys how to draw lines on your manifolds, and turbine housings, etc and it'll be up to you to stay in the lines. Don't worry though it'll take quite a bit of effort to mess up, lol.

I don't have one anymore but i know quite a few. Cough troll ivan matt.

97TurboDSM · 11-30-2005, 02:12 PM

im in!

**TROLL** · 11-30-2005, 02:22 PM

wil and i were going to port my exhaust manifold tonight but then i found out its very loud and i wouldnt be able to do that at night, even in my garage. if anyone has a garage in the area we can use then i'm still down to do it tonight but i need to knwo sooner rather than later so i can pull my manifold off!!
bryan

**TROLL** · 11-30-2005, 03:30 PM

anybody? i'll bring the tools and the headers... wil is bring the know-how... we just need a place to do it where we can be loud. need to know soon so i can get started on pulling the headers off...
bryan

sfd · 11-30-2005, 05:33 PM

id lvoe to learn.

i dont have a garage to do this in (at night) or id offer.

WhiteXFire · 11-30-2005, 06:13 PM

Man, you guys should drive down here...you can use my apt parking garage and I can learn at the same time!

Btw, I keep wanting to say "Do you like to...do it, yourself?" when I see this thread. Thanks 40 yr. old virgin...

**TROLL** · 12-06-2005, 03:04 PM

ok so on sunday i had a marathon port and polish in my garage. thanks to will for coming over for a bit and getting me started... it takes a looooong time to do the wrx exhaust manifold at least, since there are 9 different places that can be done.
i was very slow and careful on the first one and it took forever. as the day went on i got more comfortable and applied a lot more pressure and just went at it.
i dont know if my job would win any awards for looks... i wasnt quite as concerned with that as just getting them opened up and matched decently well for whatever performance gains i could achieve.
anyways, on with the photos...

complete exhaust manifold, with gaskets

comparison of ported manifold versus stock untouched. notice the carbon buildup which indicates the difference in size between the actual opening and the gasket. right off the heads you want to just open these up as much as possible, but of course keep them slightly smaller than the gasket so it can seal properly

stock crosspipe versus ported one. this pipe has a flex section in it and therefore is 'sleeved'. this sleeve creates an abrupt step which you want to grind to a much smoother transition

port matching requires matching the outlet of one pipe as closely as possible to the inlet of the pipe that bolts up to it. to do this i took a sheet of posterboard on the larger of the two and cut a template of the exact opening size. i laid it onto the smaller one and basically grinded away until it matched the template. yes i know my template is ghetto but i just used it as a rough guide. also notice that i didnt open up the inlet as much as possible... thats the point here, you only want to open it as much as is needed to match the pipe it is being mated to.

and here are some finished product shots...

oh and i almost forgot to mention... arguably the biggest benefit to this mod is the mad tite weight savings yo

TalonTsi97 · 12-06-2005, 03:07 PM

Looks good for first try. Hope it helps you out.

Intercooled T · 12-06-2005, 03:08 PM

good pictures and comparisons. weight isn't really an issue, but how much did you widen the manifold?

11-30-2005, 10:10 AM	#1
2point4DSM Tri-State Post Whore Join Date: Jun 2005 Member #505 My Ride: 08 Sienna Limited AWD, 07 John Deere riding mower, 03 Honda Pilot, 92 GSX iTrader: (0)	How-to DIY Port and Polish First off, tools make the difference. Having top end and torque is good. With that said, electric is awesome cause it has both. People's opinions may vary. Of course if you could dump $300++ into an air die grinder then I would probably have to reconsider. Anyway, never port and polish parts on a car if you have to lay on your back to do it. I had a buddy that got a splinter in his eye doing it this way, lol. Most people would say that port matching is the best bang for the buck. Keeping the intake side a bit rough and polishing the exhaust side seems to be the ideal way. __________________ - Wil 08 Sienna, limited AWD w/ laser guided cruise control, FTMFW!

11-30-2005, 10:12 AM	#2
MuddyREX Tri-State Post Whore Join Date: Jan 2005 Location: Perkasie, PA Member #82 My Ride: 02 Subaru WRX iTrader: (4)	Did you do some P&P yourself? If so, what parts did you do and how about some before/after pics? __________________ The original, since 1979. <---- 190,000 mile WRX - Gone To view links or images in signatures your post count must be 10 or greater. You currently have 0 signatures.

11-30-2005, 10:21 AM	#3
2point4DSM Tri-State Post Whore Join Date: Jun 2005 Member #505 My Ride: 08 Sienna Limited AWD, 07 John Deere riding mower, 03 Honda Pilot, 92 GSX iTrader: (0)	Sorry no pics. After an hour or more of porting and polishing my hand would never be stable enough to hold a camera, lol. But yes, I've done quite a few jobs. I've done several heads, intake and exhaust manifolds, turbine housings, throttle bodies, o2 housings, etc. I started doing it over ten years ago. Lately, I dread the idea of doing anymore jobs. Very time consuming and messy, lol. It's not hard. Just takes a lot of patience and some background knowledge. For example you can't really go crazy on a head cause you can poke open an coolant passage. At that point you can throw the head aways, lol. __________________ - Wil 08 Sienna, limited AWD w/ laser guided cruise control, FTMFW!

11-30-2005, 10:26 AM	#4
igo4bmx Tri-State Post Whore Join Date: Jun 2005 Location: Under the bar... Member #592 My Ride: 2009 Audi A3 Quattro, 2008 BMW X5, 2003 WW Evo8, 2000 Turbo SOHC Civic iTrader: (1)	http://www.sa-motorsports.com/diyport.shtm __________________ BOOST doesn't get you laid. Roofies and some creativity does however Tuned by some white dude @ a shopwithbigtrucks.com "You get what you pay for" - thanks captain obvious, unless you bought rotas and received volks.

11-30-2005, 10:29 AM	#5
moorefire Tri-State Aficionado Join Date: Mar 2005 Location: easton, pa Member #241 My Ride: MS13 - V35 iTrader: (0)	heres a good circle track tech article on porting http://circletrack.com/techarticles/...5_intake_flow/ __________________ -Will

11-30-2005, 10:33 AM	#6
2point4DSM Tri-State Post Whore Join Date: Jun 2005 Member #505 My Ride: 08 Sienna Limited AWD, 07 John Deere riding mower, 03 Honda Pilot, 92 GSX iTrader: (0)	Also, a lot of people go crazy and take a lot of metal out of exhaust parts. Not really a good idea cause the more mass you take out the sooner it will crack. Of course, if you plan on upgrading to that super duper tubular setup in the near future anyway, then go ahead, go crazy... lol. __________________ - Wil 08 Sienna, limited AWD w/ laser guided cruise control, FTMFW!

11-30-2005, 11:12 AM	#8
MuddyREX Tri-State Post Whore Join Date: Jan 2005 Location: Perkasie, PA Member #82 My Ride: 02 Subaru WRX iTrader: (4)	Seriously, I would never have the balls to try and tackle something like this without seeing it done first. __________________ The original, since 1979. <---- 190,000 mile WRX - Gone To view links or images in signatures your post count must be 10 or greater. You currently have 0 signatures.

11-30-2005, 11:48 AM	#10
sur4die Tri-State Aficionado Join Date: Sep 2005 Location: Somerdale Member #899 iTrader: (0)	i'm in! free (as in beer) modifications are the best! __________________ Got Wagon?

11-30-2005, 12:36 PM	#11
2point4DSM Tri-State Post Whore Join Date: Jun 2005 Member #505 My Ride: 08 Sienna Limited AWD, 07 John Deere riding mower, 03 Honda Pilot, 92 GSX iTrader: (0)	Barry, we need a garage to do this all in. How big did you say your garage is? I'll show you guys how to draw lines on your manifolds, and turbine housings, etc and it'll be up to you to stay in the lines. Don't worry though it'll take quite a bit of effort to mess up, lol. __________________ - Wil 08 Sienna, limited AWD w/ laser guided cruise control, FTMFW!

11-30-2005, 02:12 PM	#13
97TurboDSM TST Ruined My Life! Join Date: Sep 2005 Member #849 My Ride: '03 IY 20th GTI iTrader: (3)	im in!

11-30-2005, 05:33 PM	#16
sfd Tri-State Addict Join Date: May 2005 Member #405 iTrader: (0)	id lvoe to learn. i dont have a garage to do this in (at night) or id offer.

11-30-2005, 06:13 PM	#17
WhiteXFire Tri-State Post Whore Join Date: Apr 2005 Location: Langhorne, PA Member #305 My Ride: 2007 Infiniti G35x, 2008 MB SLK55 AMG iTrader: (0)	Man, you guys should drive down here...you can use my apt parking garage and I can learn at the same time! Btw, I keep wanting to say "Do you like to...do it, yourself?" when I see this thread. Thanks 40 yr. old virgin... __________________ Just enjoying the ride. To view links or images in signatures your post count must be 10 or greater. You currently have 0 signatures. 2004 Chrysler Crossfire - Gone 2007 Infiniti G35x Sedan - To view links or images in signatures your post count must be 10 or greater. You currently have 0 signatures. 2008 Mercedes-Benz SLK55 AMG - To view links or images in signatures your post count must be 10 or greater. You currently have 0 signatures.

12-06-2005, 03:07 PM	#19
TalonTsi97 TST Ruined My Life! Join Date: Jan 2005 Member #136 My Ride: 1997 Eagle Talon iTrader: (21)	Looks good for first try. Hope it helps you out. __________________ 1997 Eagle Talon Tsi To view links or images in signatures your post count must be 10 or greater. You currently have 0 signatures. Updated weekly with Dyno, Track, AutoX, Street, and Event videos. Big updates coming soon! To view links or images in signatures your post count must be 10 or greater. You currently have 0 signatures.

12-06-2005, 03:08 PM	#20
Intercooled T Tri-State Post Whore Join Date: Mar 2005 Location: Fairless Hills, PA Member #207 My Ride: 2003 Toyota Rav4 iTrader: (0)	good pictures and comparisons. weight isn't really an issue, but how much did you widen the manifold? __________________ 2003 Toyota Rav4, 2.0L/Auto/AWD To view links or images in signatures your post count must be 10 or greater. You currently have 0 signatures. 2013 Nissan Juke, 1.6T/Auto/FWD (wife's car lol To view links or images in signatures your post count must be 10 or greater. You currently have 0 signatures. )

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