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"FFTec did my T-Belt job in a few hours. It would have been faster but I also had them do my lifters and
water pump. Good work though. I highly recommend 'em."

-DSMTuners Member

FULL FUNCTION - PORT MATCHING AN INTAKE MANIFOLD FOR A OVERBORE THROTTLE BODY

Port matching an intake manifold for an overbore throttle body

When trying to maximize your engine’s output, a larger throttle body becomes a necessity. Factory engines often bottle neck airflow at the throttle body restricting airflow. An engine short on air will fall short of its potential horsepower. While modified engines see the largest gains from induction modifications, a stock engine will still benefit from a throttle body upgrade. A larger throttle body is a good compliment to other induction enhancers, such as intake systems and larger turbochargers.

When upgrading your throttle body there are several issues a person may run into. They range anywhere from sensors and solenoids not fitting to port size of the throttle body and manifold. We are only going to address the port size here. When installing a larger throttle body on your intake manifold it may be necessary to port the intake manifold's inlet to match the new throttle body.

For this article we will be match porting a 1995 Mitsubishi Eclipse for a 1993 throttle body . This task can be accomplished either on the vehicle or off. If you plan on doing this on the car mask off the entire engine bay and block off the intake manifold with rags. Be sure to vacuum ALL the shavings out of the manifold once porting is complete. Getting aluminum shavings into the motor will cause damage. The porting process will send material all over so it is a good idea to cover up the entire engine bay to keep clean up time to a minimum.

Tools Required:

* Air die grinder or dremel
* Carbide cutting bits
* Medium grit cartridge rolls

Clean the surface of the intake manifold reasonably well and set the gasket of the new throttle body on it. Use some bolts to center the gasket as it would sit during installation. Scribe a line along the inside of the gasket's diameter. Remove the gasket and clean the surface off once more.

Once the surface is cleaned off again use some dye or permanent marker to fill in the scribed mark. In this case we just used a permanent marker and wiped it off before it all dried. This should leave a clear easy to see line where the porting should finish off. At this point your should block off the intake manifold with some rags or tape to keep shavings from getting inside.

If this is your first time porting aluminum start off with a slow speed. Going too fast will only clog up the bits and slow the whole process down. Once you get a feel for how the metal is cutting you can speed up the dremel/die grinder's speed. Take note of the hand position of our technician. He has one hand firmly holding the dremel and his other hand is stabilizing the dremel by supporting it with his thumb and placing his fingers on the manifold. This greatly increases the control of the porting technique.

We used the carbide cutting bit with large teeth to clear out large amounts of material quickly. Once most of the material was removed we switched over to the Medium grit cartridge rolls to inch up on the scribbled mark. The medium grit does a great job of giving a clean but not overly smooth finish to the ported area. Now you vacuum out ALL of the shavings, pull out the tape/rags and put the car back together.

 
   

 

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