Intake Porting, Day 1 Options

[SpedToe169]

I started porting my spare intake today. Wow, what a mess. This intake came off John's (mynzeyes) motor. I'm sure this motor was relatively well cared for but man it had a lot of gunk in it!! Heres what it looked like when I split the intake halves:



As you can see, there is a lot of built up crud on there. I spent today mostly cleaning it up with the dremel, getting the gunk off, smoothing casting marks and the like. I worked really hard on one of the dividers and 2 runners have the plenum side almost done.

Its going to be impossible to reach all the way through the runners, they're just too long. What I'm going to do is get the runner shapes and sizes the way I want then sandblast the thing. The sand will act similarly to the extrude hone process and remove the grime and somewhat smooth the surface finish.

I'm really pretty impressed with toyotas engineering so far. The surface finish on the inside of the manifold isn't bad once you get past the dirt. The runner shapes are a little screwy where they exit the plenum but I think I can make it work. Also the plenum is a little strange....not like anything I've ever seen before. You'll probably be able to see what I'm talking about in the pictures....the dead space (why a plenum works so it has to be there) is really really irregularly shaped. The only thing I can think of is that it just worked out to do it that way. As of now I'm not sure that I'm going to mess with the actual plenum shape much, I think I'm going to focus on the runners from the plenum to the head and the interface between the TB and the plenum.

Heres what it looks like after tonight. The right two runners are getting close to being done. Its really hard to see in the picture how exactly they've been reshaped, but trust me, they're different.