Just thought I would share my progress. I picked up a used OEM intake manifold, sent it to Fullblown to have it ported to match their 74mm throttle body. When I got it back I decided that I wanted to have it powdercoated in a semi-gloss black. In prep for powdercoating I decided to sand all the casting marks off (mostly just the surfaces that are visible when the IM is installed).

I have never taken on a project like this. I bought a 30gallon air compressor, a few air tools, many sanding disks, etc. Most of the work was done with a 90 degree die grinder, 4" grinder, and a dremel.

All vacuum ports were shaved and filled (except brake booster port)


Secondary air injection port shaved and filled


Water ports shaved and filled


Fairly smooth


New home for the AIT sensor


Almost ready for powdercoating! Will post more pics when I get it back.

Scott-

 

Looks nice, but I don't understand why you didn't just port match the TB flange yourself, since you already have the tools to make quick work of it. If I was going to send it off anywhere to have something done to it, I would have had it extrude honed on the inside.

 

I didn't feel comfortable doing the TB opening myself at the time. I knew that there was going to be some welding involved when opening the port up that large. Actually I didn't buy my compressor / air tools until after the IM came back from Fullblown.

At this point if I were to do it again, I would def do the TB opening myself!

Scott-

 

Dont paint it! It looks great.

 

what are you doing with the coolant port next to cyl. 1 runner and the coolant port on the t-stat housing..

 

Are you talking about the port right by the bleeder valve? If so, I have tapped it to accept a M6 bolt and will plug it with a bolt.

 

This looks great!

When you say 'filled', what do you fill the holes and gaps with?

 

I took it to a local welding shop that does a lot of aluminum welding. They filled in all the holes for me. Cost was $50.

 

Gonns look sweet! How big were they able to bore out the intake manifold?

 

Thanks Ryan! Fullblown matched it up to their 74mm throttle body