DIY plenum porting
#561
New Member
iTrader: (15)
AWESOME DISCOVERY: an amazing way to clean the plenums of dirt and oil is to use AIRPLANE PAINT STRIPPER. Spray or brush it on, wait a minute or two, and rinse. No scrubbing at all. Comes out looking better than new.
I've used various grades or degreasers, detergents, brake cleaner, gasoline, acetone, paint thinner, engine degreaser, even steam clean. AIRPLANE PAINT STRIPPER hands down is the easiest, fastest, product to use with the best results possible
I've used various grades or degreasers, detergents, brake cleaner, gasoline, acetone, paint thinner, engine degreaser, even steam clean. AIRPLANE PAINT STRIPPER hands down is the easiest, fastest, product to use with the best results possible
I will try this when I clean up my plenum pre-installation
#562
Registered User
iTrader: (10)
re
This isn't that big of a deal with an angle grinder and sanding discs. Just use several grits, don't go crazy, and a little trick to make the disc last longer: sand a stick of wax for a quick second, just enough to get a thin layer of wax on the disc. This will make the discs last longer. Little trick the pros use.
#563
New Member
iTrader: (15)
Alright guys! Finished my lower runners tonight! Took some pictures with my cell phone; First pic is of the heads' side, second pic is of the lower plenum side; third pic is a close-up of one of the runners to the head; and fourth pic is a close-up of one of the runners from the lower plenum.
Very shiny! But trust me, it's not super smooth. I didn't smooth it out too much, just polished with some aluminum polish and I will clean the whole thing off with some of that airplane paint stripper before I paint it!
Very shiny! But trust me, it's not super smooth. I didn't smooth it out too much, just polished with some aluminum polish and I will clean the whole thing off with some of that airplane paint stripper before I paint it!
#564
New Member
iTrader: (15)
Some pictures to keep folks entertained:
I'm about to tape off the lower plenum right now to prepare for wrinkle coat on the exterior of that as well. I will post more pics when I get it painted, and when it's installed / comparison to the old one that's on the car now.
I'm about to tape off the lower plenum right now to prepare for wrinkle coat on the exterior of that as well. I will post more pics when I get it painted, and when it's installed / comparison to the old one that's on the car now.
#567
New Member
iTrader: (15)
I heard the same as well Rob. But I've also read that it really only applies to carbureted engines, and only in parts of the engine where the fuel mixes with incoming air. So I'm really hoping that it being too smooth doesn't affect it in a bad way. I just sprayed the lower plenum exterior last night, so that's drying all day today and I will be installing everything tomorrow. I also just installed my single exit exhaust Wednesday, so I hope that combined with the exhaust, I really feel some improvements tomorrow.
#569
New Member
iTrader: (15)
Hahaha yeah exactly, that's why I figured I'd just go for it and smooth it out. I only went up to 220 grit.
Either way, it should sound freaking sick, especially because I'm doing the upper plenum (which is also cast flashed and polished) and the 3/8" spacer. I'm really excited to get it all on.
Either way, it should sound freaking sick, especially because I'm doing the upper plenum (which is also cast flashed and polished) and the 3/8" spacer. I'm really excited to get it all on.
#570
New Member
iTrader: (58)
^- your work looks very, very good... I did the same thing to the lower plenum minus the runners below... didn't have the necessary tools to get in those tight spaces :/ I did however smoothen it out as much as I could by hand sanding but not extensively... oh well maybe every little bit can help
any thoughts on dynoing?
any thoughts on dynoing?
Last edited by Voboy; 04-30-2011 at 10:48 AM.
#572
Registered User
iTrader: (9)
Pfregeolle would have to do a before any after dyno one after the other within a relatively short period of time so that all parameters are roughly the same.
Pfregeolle would more than likely have to pay for 2 sets of dynos as well
Im sure all of us would be interested in those numbers though
Pfregeolle would more than likely have to pay for 2 sets of dynos as well
Im sure all of us would be interested in those numbers though
#573
New Member
iTrader: (15)
^- your work looks very, very good... I did the same thing to the lower plenum minus the runners below... didn't have the necessary tools to get in those tight spaces :/ I did however smoothen it out as much as I could by hand sanding but not extensively... oh well maybe every little bit can help
any thoughts on dynoing?
any thoughts on dynoing?
Tools I used included a sander and some REALLY low grit paper to take the front two runners down about 6mm. A dremel tool with some 80 and 120 grit flap sander bits for getting into the runners. And some aluminum oxide sandpaper from 60 grit up to 220 grit, and a little of 1000 grit in a few spots to really smooth it out. Honestly a majority of it was done by hand, which REALLY SUCKS! I probably would never do this again. If I did, I might do the Intake Manifold (lower runners) again because that was the easiest part of the whole process. And maybe try and sell them or something. I put way too much time into all this hahaha But I guess it's worth it. Overall this has been a year-long project. But you have to remember I flashed and polished both the upper and lower plenums and the intake manifold. So probably a good 60 hours or something retarded like that. I just installed everything yesterday, I have a few shotty cell phone pix from my Facebook, but I also took photos during the install and I will post up the good ones tonight. In the meantime here are the cell phone photos:
#576
New Member
iTrader: (15)
I was just about to post a link for you haha But did you find out what the casting flash was?? If not, refer here:
http://www.aircooledtech.com/casting_flash/
Basically just getting rid of all the excess aluminum inside the runners from when the plenums and manifolds are produced. Less air flow restriction.
http://www.aircooledtech.com/casting_flash/
Basically just getting rid of all the excess aluminum inside the runners from when the plenums and manifolds are produced. Less air flow restriction.
#580
I picked up a non revup lower plenum to port out a bit. How much should I take down the front runner? Two posts up says the mrev is shaved down 5mm, is that the 'best' or optimum amount?
Work from pfregeolle above looks awesome. Might have to buy a dremel now, was gonna tackle this with a grinder, files, and sandpaper.
Work from pfregeolle above looks awesome. Might have to buy a dremel now, was gonna tackle this with a grinder, files, and sandpaper.