I bought a set of gauges and wanted to do a very clean install. I didnt want to cut my heatshield so I decided to tap from underneath. So... since i was pulling my exhaust manifold off maybe i should port it, and since the manifold is off i might as well do an O2 housing and since all the hot stuff is off, maybe i should ceramic coat it.

Here are some pics of the build. Pretty straight forward on the install. Thanks to Jersey Dino for his write up on the O2 housing.



Let the porting begin:


Roommate did the porting. Double cut carbide bits FTMFW. Goggles came on after the second shard of iron went in his eye:




Notice the difference in port sizes. This was really the ONLY poor stock casting. Everything else was very close to gasket matched:



One port left:


Hot side has a really nice stock casting so we really just polished it up on the exhaust in and out. Did not feel wastegate was worth the time.

Before:


After (feels like glass):


And cleaned up the twins:


Sandblasted:



yada yada yada:


Coated:



And installed a Forge UNOs:


Final product:


Impressions:
I think the final product came out awesome. Spool is definitely faster from what i can tell. Car still has to be tuned. I also installed a GM 3 port (yes GM 3 port BCS AND MBC) so it was overboosting a lot (let off at 26 psi). Right now i have everything happy with the MBC taking over and holding 19psi. I have to take some logs to see what is going on i just haven't had time.

 

depending on the type of egt probe (exposed/shrouded) you use...they all will become brittle and break off or drift due to carburization

you have to take of mani to change it?

nice job on the porting!

 

DIY ceramic coating or did you send the stuff out?

 

on the manifold, you don't really want to gasket match the head side. if you notice, the manifold is almost exactly the same port size as the head. the gasket is much larger then the ports on both the manifold and head. so really, the stock casting is pretty good. on the turbo side of the manifold it is a different story

 

Probably. It isnt incredibly difficult to take off though and is only about a 45 minutes job. I MIGHT be able to get to the probe without taking it off but i will pass that bridge when need be.

 

Looks good... boy you have a lot of stuff if you can do that in your basement!

Maybe I should start taking pieces off to do that haha..

 

yeah basement has a diesel workshop. Sandblasting cabinet, 60 gallon 2 stage compressor, and all the porting bits you can imagine. Not to mention Queen and Journey CDs.

 

props for doing it yourself

 

looks better in person. but i'm waiting for seat time to verify

 

Looks awesome man. Keep up the good work!!

Jason

 

Be careful changing oil next time, you might end up rebuilding the block!
Great work!

 

Curious about this....

Is there a way to Ceramic Coat by a DIY method?

Links?

 

We used this:
http://www.techlinecoatings.com/Exhaust.htm
Black satin

First we media blasted everything using 120 grit aluminum oxide as the manufacturer recommends. Then using an air paint gun, sprayed everything down and baked it in the oven at 550 for an hour or until it stops smoking. Most exhaust parts will cure more on the car. My roommate has been using it for a while. I would highly recommend the correct media as he had some older stuff using the wrong media and it flaked off after about a year. This stuff is very durable once cured.

 

Haha it is true. I mean since the oil is already drained.

 

did you want to try the nitrous? ill bring it tonight.