Ok I know there is another thread on here about how to remove your IM and TB so IM just going to stick to the porting process. For all of you who think you cant port your own IM, youre wrong. A kindergardner who can draw inside the lines could port an IM. So here we go.
First remove your Intake Manifold :
Next clean the hell out of it. There is going to be alot of nasty black and brown stuff coming out. Youre going to want to buy an intake manifold and throttle body cleaner from an auto parts store.
You can actually place the IM in a wash sink, or outside and flush it with water when youre done with the cleaner. CAUTION !!! wear safety glasses and do this in a well ventilated area, that cleaner is nasty stuff and the manifold has a way of shooting it back at ya.
Next step, buy an IM gasket and place it over the IM where it would go in the car, hold it in place by putting a few bolts through the holes as you would on the car. With a paint pen or big sharpie fill in the metal that shows inside the holes of the gasket. Should look like this when youre done.
Ok, now youre going to want to set some blocks up so the IM sits solidly on your work bench. Now get your dremel and a supply of grinding bits. I used 3 or 4 different sizes untill i found one that worked for me. They have tons of sizes so just pick one that works for you. These are the types of bits they use for sharpening chainsaw blades mostly. Have a can of WD40 ready to go, youre going to want to keep spraying the bit and the manifold to keep heat down and keep the shavings flushing away.
You want to keep removing material slowly untill all the black area is gone (see above) and you want to go back into the manifold as far as you can (2 -2.5 inches) KEEP SPRAYING WD40, trust me it sucks if you dont.
When you are all done go back and use alot of the cleaner again. You need to get all the shavings out. alternate between cleaner and hot water flushing. I also found that taping a rag to the end of a stick or thick wire and then stuffing it down the IM helped free things up to be flushed out.
Should look something like this when youre done and cleaned out.
Now re-install.
Hope this was helpful. If anyone wants to try this out Ive got a stock IM ill sell for 85$ shipped. This way your car doesnt have to be down while you work on the IM.
