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The fully port matched intake manifold. The layout markings have been cleaned and the manifold is ready to be installed.
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With the exception of the die grinder, here are the basic items utilized in the project. The machinist's layout fluid (Dykem Red), two telescoping gauges to measure inside dimensions, two "open pitch" carbide bits, mandrels, 80 grit sanding rolls, and cross buffs.
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With layout fluid painted around the ports, the intake gasket is bolted in place displaying the material that will be removed. The port dimension is then scribed onto the intake manifold using the gasket as a template.
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The gasket that was used as a template is now removed. Failure to remove the gasket is a sure fire way to ruin it and will require the purchase of a new one to complete the intake installation.
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With the air pressure set at 40 psi and using the "football" shaped carbide bit, begin to remove material from the port entry. As you work in an up and down and circular pattern on each surface, remove material in a controlled manner. A heavy hand can quickly get you beyond the scribed guidelines ruining the port's shape.
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Now begin to open the runner and enlarge the rectangular shape of the port runner by shaping each corner toward the plenum. Once the opening is to size, a pinch point has been created just inside the port opening. This point must be blended up the intake runner about 1.5" to insure proper air flow through the runner and into the cylinder head.
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Using the intake gasket for dimensional purposes, horizontal and vertical measurements are taken with a caliper. These measurements are then transferred over to the telescoping gauges.
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With the port's vertical dimension transferred to the telescoping gauge, check the port for size. Here you can see that the gauge just enters the port clearly displaying a "pinch point" in the runner. More material must be removed to further shape the runner. A smooth transition is critical, so take your time.
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The runner is now taking shape with the height held to the vertical dimension into the runner the desired 1-1/2 inches.
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Using your second telescoping gauge set to the width dimension of the intake gasket, maintain a smooth transition up toward the plenum. The shaping of the runner's width has followed the same "shape, stop and measure" process undertaken while you increased the height.
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With the port entrance and runner closely shaped to both height and width dimensions, you can now begin to smooth and finish the port opening and runner. 80-grit sanding rolls are perfect for this step. Start with a small diameter, 3/8-inch roll to shape the corner radii of the port, then move up to a 1/2-inch sanding roll to further shape the flat surfaces. Remove your glove and run a finger up the runner to insure you have no waves in the wall surfaces.
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Our gasket matched port and blended runner is complete. Now only seven more to go!
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