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Old 04-04-2010, 10:30 AM   Thread Starter #1
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Default How to Port and Polish Your Manifold

Source: http://www.bethandjames.com/exhaust_...ld_porting.htm


1. Take off the exhaust manifold.

2. Port the exhaust manifold to gasket size but don't touch the exhaust port itself. Aim for a .040" - .100" lip on the head side. You can use something like a Dewalt DW887 die grinder with a dimmer switch to control the speed for the heavy grinding and a Dremel for final touch up. Get a set of carbide burrs for the meaty stuff and a set of rolls for clean up. Standard Abrasives makes great porting kits with all the rolls you'll need. Flow won't be impacted by the increase in diameter, but reversion will be assisted by the step down. The idea is to keep the exhaust gas flowing in one direction avoid mixing burnt and fresh mixture in the chamber, compromising detonation.

3. Get the down pipe, weld the outside and grind down the welded internal lip. Refer to pics below.

Further option 1: Once everything is ported, have the manifolds media blasted and prepped for a coating of POR 15 high temp manifold paint in satin silver as it's rated for 1400 degrees and resists salt. Feel free to coat both inside and outside.

Further option 2: wrap the manifolds with header wrap.

4. Reassemble, re-using the existing gasket.

Should take two to three hours, excluding the manifold painting and header wrapping.

Some pics, (thanks to Jettafanatic):
Down-pipe before: note large protruding weld:


Click the image to open in full size.


Down-pipe after: Note much bigger / smoother bore and no internal "lip" from the weld to cause turbulence:
Click the image to open in full size.
DP ports of the exhaust manifold after / before:
Click the image to open in full size.

Before / after head ports of Exhaust manifold: see how much more even / smooth and matched they can be:


Click the image to open in full size.








I will be doing this some time over the next couple of weeks so i will post pictures of it being done to our car

Last edited by CleanMaxx; 04-04-2010 at 01:16 PM.
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Old 04-04-2010, 12:30 PM   #2
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Default Re: How to Port and Polish Your Manifold

Nice write up dude. I appreciate that. The title needs to be changed though.
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Old 04-04-2010, 12:35 PM   #3
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Default Re: How to Port and Polish Your Manifold

nice....good write up
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Old 04-04-2010, 11:44 PM   #4
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Default Re: How to Port and Polish Your Manifold

+1 bro.. Great info.
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