going to do it myself and any hints are welcome. should I open the runners that large to match the gasket ? don't want to port too much to make a hole in the wall

 

do not port the head flange on the manifold to the gasket. you can open it up but do not port match it.

as for the manifold to turbo yes that side you can port match to the gasket.

 

Make sure to use a double cut carbide bit. It helps have to have different shapes and extras. I tried to port the manifold on my DSM back in the day using grinding stones, it's possible, but using a carbide bur is 100000 x better.

Also, you can get by with a dremel, but a die grinder will make the job much easier/faster

 

thanks for reply guys

more hints please

 

Why is this? PPI ports the individual runner ports matched to the head in their extreme porting service...

 

port matching the runners to the head is perfect. but port matching the runners to the gasket is a no no. the gasket is much much bigger then the head and manifold runners.

 

Well the only way I know to port match the manifold to head is to use the gasket as a template on each piece, use a sharpie to color the area to be ground, and then grind out what you sharpied. However.. this requires the head to be ground also to be properly port matched. Why is this a no no?

 

AFAIK you cant port match the head to the gasket. its just to big. to much material will be removed. so porting the runners on the exhaust manifold to the gasket is only going to cause turbulence in the exhaust gases. put a gasket on the head. look at how much bigger the gasket is then the head ports.

 

use some carbide burs get the long ones if you can so you can get deep in ther also clean it up with some stone bits and sand paper wheels then polish to a shine you want it super smooth

 

Yea, I don't know. I never had one of these engines apart to see. I do know that's how they do it on V8's so I assume it would be the same procedure... maybe not

 

take it apart and look. actually mine is apart. if i remember tonight ill snap a pic for you to show you. but basically you can not port match the head or the manifold runners to the gasket. its just way to much material. you will ruin the head.

as for the manifold to turbine housing you can port match that with out issues.

 

Also, if the gasket is that big.. you can still use it as a template and a dial caliper to get everything pretty closely matched without going to the gasket size.. I suppose ...

 

why not just use a measuring caliper on the head. then use it on the runners and port to match the head? my head is ported and i do not have a stock exhaust manifold but if you like i can measure it so you get a better idea.

 

Just thinking here... I think maybe still using the gasket as a template and a sharpie, it would be easier to see and measure the differences in the head and manifold ports. Yes you can measure the actual port size but you also need to know where the ports are exactly located in relation to the bolt holes. That's what using the gasket, sharpie and a dial caliper can tell you easily. For example.. you might have to grind one side of the port a little more then the other..,

 

Roger that!