Hi guys. Have a new turbo and O2 going on this weekend and currently have the manifold off. Was thinking I may as well port it all up. I have the tools to do it but had a couple of questions before I leap into it for someone in the know.

Firstly the head to manifold side. I am not interested in going to far with this, its a little to risky for me to do myself I am not going to bother with matching the ports but is it wise for me to just remove any jagged edges on this side of the manifold and then polish the runners as far down as I can.

Manifold to turbo and turbo to O2, do I take out as much material as I can to enlarge the opening to the size of the gasket at each flange and blend that back through the runners?

Thanks.

 

good luck

i plan on attempting to port my stuff later also

 

From what I understand (correct me if im wrong) you want to match the gasket to the exhaust ports on the head. Then you take your gasket and trace it onto the manifold (use a fine sharpie or something). Then that will be your guide line to how much you need to remove. You want to remove any jagged edges if any and try to smooth out any sharp corners to a rounder radius.

 

The gasket is larger then the ports on the head so that would mean doing some work on the head ports which is an area I don't want to start playing with. For that reason I don't want to start taking a lot of material out of that side of the manifold because more then likely it will just cause a larger mismatch. My interest is in whether I not I am right to clean any jagged edges off the inlets to the runners on that side of the manifold and then whether I should be doing a full gasket match job on the turbo side of the manifold and turbo to O2 flange and then polish as much of it as possible.

 

Correct, the gasket is too large for the ports on the head. The Turbo to manifold gasket is similar in size to the hotside so that part you can gasket match but it is also wise to port the hotside too.

 

Yeah my intention was to match that side of the manifold to the gasket and also match the hotside and O2 housing to gaskets.

 

what 02 housing are you running?

 

Do not port the head side of the manifold, only the turbo side. Take the gasket, line up the bolt holes, and use a sharpie to mark where on the manifold needs to be ported. Just smooth everything out inside as far up as you can reach. It helps to clamp the manifold to a table to secure it so that your hands can be free using the grinder. You will be surprised at the amount of material that you take off when you unclamp the mani from the table!

 

^what jim said. and don't try this with a dremel. you'll spend twice as much money on grinding stones as it would cost to buy one already ported.

 

Thanks. That's about exactly what I was planning to do. I wont touch the head side of the manifold at all as far as porting goes ill just polish it all up and then gasket match everything else.

I have an air powered die grinder that I will be using to take the material out and I need to go and buy a polishing stone for it to do all the polishing work.

I'm using an Invidia O2.

Oh and while I remember is there anything I need to be careful of taking the hotside off of the turbo so I can port it out? Obviously mark it so I know where to line it up again :P.

 

Fyi polishing does nothing so that is an area not worth spending any time on.

 

I have seen a few people now say to make the surface inside the manifold as smooth as possible, is this not the case? Why?