I picked up a used OEM intake manifold and shipped it out to Fullblown to have them port match it to their 74mm throttle body.

When I got it back I decided that I would try sanding all the casting marks off and shaving whatever I could off of it (in prep for powdercoat).

I picked it up today so wanted to post up some pics

Smooth


The Fullblown TB is a nice piece


Side by side


Shaving the secondary air injection port was a lot of work!


Almost ready to bolt back up



I've never tackled a project like this...pretty time consuming but a good experience

Scott-

 

FML, thanks for giving me yet another thing to do on my motor.. That seriously looks amazing, any way you could break down what all was done?

 

And can I please get rid of my IACV?

 

I came this close to doing this same thing while my IM was off after getting the head fixed. I figured the money for it could be saved for something elsewhere, but nevertheless, this definitely looks really, REALLY good.

Good job, and thanks for sharing

 

Thanks man!...not near as much work as you've done, but I appreciate it.

- sent it off to FB to have it port matched (if I were to do it again, I would port it myself)

- used a 4" grinder to grind off most of the big stuff (the risers on runners 1&4 where the fuel rail bolts up, and the other crap that has no use)

- cut off all the vacuum ports (except the one for the brake booster, that will feed a vacuum distribution block). Then used a punch to punch out the steel inserts (did this on the water ports as well).

- cut out the secondary air injection port (lots of small cuts/angles to get all the material removed)

- after all the vacuum/water ports were shaved and air injection port was gone, I took it down to an aluminum welding shop and they filled all the holes for me.

- sand, sand, sand...majority of the sanding was done with a 90 degree die grinder and different grit 2" and 3" pads. I also did a lot of block sanding by hand on the flat surfaces. Lots of angles and hard to reach spots on the IM.

- relocated the AIT sensor to inbetween runners 3&4, but low so it isn't very noticable.

Having never done this before, I think I have about 45hrs into it.

 

wow looks amazing

 

its funny you post this, i am currently doing the exact same thing to my intake manifold! looks nice!

 

Great job

Those two manifolds look different. Look at the runners


Are they both AP1/AP2 ?

 

Damn I think you are right...will have to go take a closer look!

My car is an '04 and the IM I picked up was from an AP1...I thought '00-'05 were the same

 

How far along are you?

Are you shaving all the vac ports as well?