i'm going to port the o2 housing and exhaust manifold...I was wondering would it be wise to port the intake manifold as well? Are the gaskets reusable? (i'm a cheap bastard/college student)

 

anyone?

 

I have always wondered what the inside of a stock evo 8 plenum looked like. Especially after seeing some poor finish quality of other components, i.e. the combustion chamber!!

If you have the time, see about reducing the throttle blade by 1/2 if it looks strong enough. Threads only go into 1 side anyways & check into having some put the throttle blade on a surface grinder & take it down a bit too if it's very thick. Use button head screws to put it back together.

I havent seen or touched either components, just something that comes to mind as an easy mod on production components.

 

"Do not match the exhaust manifold to the gasket, it is way oversized."
Quoted from Dave Buschur.
I wouldn't weaken the throttle blade. If it breaks, so does your motor.
I have my intake manifold off right now. I just checked the intake, vrs gasket and intake ports vrs gasket.
The head matches up to the gasket almost perfect, but lots of casting flash in ports, and valves are really shrouded in chambers also.
The intake runners have about .5-1mm of material along the bottom of each that need to be removed to match the gasket, the sides and top are pretty close, maybe some light touch up to make it perfect.
Inside the intake runners don't look too bad. Not really smooth, but not much flash either.
I cleaned up my turbine housing, O2 housing, and matched the exhaust manifold to the turbine housing. I also did some light cleanup on exh manifold itself.
The O2 housing needs the most attention and the nozzle outlets leading into the turbine were boogered up good. I used a small hand file on this area, so I didn't screw up anything.
I just pulled it apart after 14k miles, and there was very list carbon on the cleaned up areas, inside the exh manifold had a good bit of carbon (where I didn't polish).