lithium15

Seeing 2000s4biturbo's post with what he did on to his intake manifold got me thinking.. How hard is that in all honesty. Just looks like it takes a bit of paitence and some work and time. It looks like all that was used was a dremel and some assorted bits. Does anyone have some insight on the topic. Heres a link to his post:

https://forums.audiworld.com/s4/msgs/1861158.phtml

and a quick pic:

<img src="http://pictureposter.audiworld.com/78292/pc280013.jpg">

Bauer

on a head I pulled off an old audi.....for it to be correct it is tuff.

lithium15

for it to be correct that is... im new to porting and polishing, his link sparked an intrest

S4mig@PEB tuning

Also you'll want hearing and eye protection, and a gallon of WD-40. Its messy and aluminum dust is a bitch. If you dont have any of that stuff, you may just want to consider paying someone else to do it.

Bauer

A good friend mine used to be a cheif mechanic for a Can Am race team back in the day. He has extensive tuning experience of N/A cars and I have watched him do a port, polish and filled in the head on a BMW he was tuning (he know owns BMW repair and tuning shop).

The difficulty lies in porting the same amount of material from each port, the same and correct shape of the porting. If you take more material out of one then another or have the wrong shape it will effect the air flow and can negate the porting all together. An Example would be if you took too much material out of the back side of the port this could cause the air to, in a way get caught or tumble. Think of a river and if there is a cut out in the bank the water can swirl in that cut out or casue a diruption in the flow. Same thing can happen if the porting is not done right.


It takes real skill and time to get it right. But if done correctly can really help with the breathing of the motor.

Again, I am no expert this is just some of the infomation I have gathered...hope it helps.

Skydive@AI

Gah! It looks like a blind monkey did that.

S4 SOM

you meant 'monkey' ?

Skydive@AI

D'oh! Fixed.

EricVonHa

You need to cut the top off the upper plenum to do it properly. Once the top is cut off then you'll need a long throw jigsaw blade or sawzall to get a head-start on cutting off the "bell-mouths" that protrude into the internal plenum area. There is no way to get any real access inside the plenum unless you cut off the top. Opening up the factory supplied access panel on the bottom does nothing for you unless you wish to do a very basic polishing of the surfaces.

Follow some of the other stuff that others have mentioned about polishing air tools are a must.. don't even think about a dremel (you'll kill it in one hour)... and throw away your clothes when you're done. Metal filings get everywhere and it gets in the house carpets faster than you know.

When it comes time to weld the roof back onto the upper plenum-- take it to a very experienced fab shop. Welding impure cast aluminum is not something the local welding shop is equipped to do!