porting and filling with epoxy

[stuart wizy]

ive just done another hour or so porting my intermediate plate intake ports and decided to port right up into the m8 tapped hole which holds the manifold on  the side plate face, ive re tapped the hole further away from port.
the full length of the 2 ports are 52mm now but ive gone as far as possoble without breaking through casting into water jacket.
im planning on filling the 2 injector holes and m8 tapped hole with epoxy resin and then porting over the top nice and smooth.
as anyone used epoxy for inside a port?
Im a little paranoid if it comes loose it will mince my housing and turbo up.

[Bucky]

I\'d use JB weld, it\'s proven to work.

[Grizzly]

If you are never going to use the holes again, drill them with a few mm over size drill to about half way down, this way you a. get a nice fresh surface to stick the epoxy too and b. if it did decide to come loose it can\'t drop into the port

[Bucky]

Or you could screw a bolt in, all the way down to the bottom of the thread and cut it off flush.

[Grizzly]

ive just done another hour or so porting my intermediate plate intake ports and decided to port right up into the m8 tapped hole which holds the manifold on  the side plate face, ive re tapped the hole further away from port.
the full length of the 2 ports are 52mm now but ive gone as far as possoble without breaking through casting into water jacket.
im planning on filling the 2 injector holes and m8 tapped hole with epoxy resin and then porting over the top nice and smooth.
as anyone used epoxy for inside a port?
Im a little paranoid if it comes loose it will mince my housing and turbo up.

I thought the idea is not to open the Runners up as big as poss? this will slow your air speed down? I thought you match the Manifold to the Port then remove the minimum  so it keeps the air speed up then smooth the port out so it flows as cleanly as you can?

Thats if your not using a Custom manifold of course.

[Bucky]

I would say you can take about 2mm from the wall thickness to open the port out. Primary\'s I\'d do about 2mm, secondary\'s I\'d go as mad as I could as the gas speed is high enough anyway.

[stuart wizy]

the inter intake ports are tiny as std, ive ported up into the m8 tapped hole parrallel to the thread, and its just breaking through.
Ive then drilled and re tapped the thread about 10mm further down out of the way, purely so i could make the port as big as possible
My aim was to make the 2 inter ports as long as poss because of there narrow width.
My secondary intakes are huge!( max width and max height)
I forgot my camera when i went in workshop earlier on, I will take a picture tommorow for you to see cause its hard to explain what i mean.
yes i am making new inlet flange to match the new inlet ports exactly, and then the runners are being welded on the flange.
The 2 inter port runners are going to have to be shaped to suit because they run 3mm apart, but the secondary intakes fit just nice with the end of the 50mm runners squashed into a oval shape.

[Grizzly]

well there is an easy way of doing the Port runners, match the outer edge of the Runner to the gasket and the manifold to the Gasket. You only need to clean up the port the worsed bit is the top left (if memory serves me correctly) which as you say is about 2mm but the other key is not to over smooth the port, i\'d finish with a 40/80\'s cone don\'t go for a Mirror. There are people that go silly with the port Flow on Bridges using Smoke machines etc.. There is not much point in Big Ports if you don\'t have matching Runners all the Way through the Inlet?? Fd\'s have very small lower Inlet manifold Runners as i found out in my T2 Days

I think the idea is to keep the Runner size the same from the Throttles to the Chamber so you can get the max Volume of gas into the bore (less presure drop in the runners)

[stuart wizy]

air speed will be the same through all my runners cause they are all the same size- 4- 50mm tube runners from plenum straight on intake ports in 1 run, no middle flange like your std setup.
The runners have been bent 180deg at 140mm radius and fit in a 130mm tube plenum, with a flange welded on plenum with 90mm throttle body bolted to this.

[Grizzly]

Right so you have made a new Inlet. That would explain why you have gone bigger i thought you had just Welded a new flange on the std manifold

Have you seen the KG manifolds? http://www.kgparts.com/jay-tech.htm There are a few Guys in the US using these and seeing big hp.

[stuart wizy]

grizly you will see what i mean tommorow when i take some pics, im shaping the end of each runner as near as dammit to match the intake ports that have been shaped already on the new stainless flange.( the runneres are 50mm stainless tube 1.5mm wall)
then the runners will be welded on to the flange, but the 2 intermediate runners are going to be tricky to weld because they are so close together so im going to have to insert them through the flange and weld them from inside the flange if you get me.

[Grizzly]

Yeh i get what your saying now, I thought you where Moding a std Inlet to run massive ports, but i see you custom making a new manifold to match. So forget what i said.

[Grizzly]

, but the 2 intermediate runners are going to be tricky to weld because they are so close together so im going to have to insert them through the flange and weld them from inside the flange if you get me.

Yup, I made a few Exhaust manifolds in my time I used to use 1/2 plate for the flanges so it was quite easy to weld from the inside.

[stuart wizy]

my mate give me a plasma cutter a bit back for playing about with.
Its cut all my bores out in my plenum, cut the 2 radius pieces that fit on rad of plenum, then i got a bit silly and lazy and tried to blast through 10mm thick stainles flange plate and the nozzle melted!!!!!!!!!!!!!! :rollin
It cuts 4 mm ok anything above this and its srugles has i found out.
Highly recomend one to anyone wanting to cut any type of shape in plate up to 4mm thick.
Its only a cheap toytown one but for making manifolds and cutting tube its suberb.
U just need mains and airline, no oxyset and gas.

[oldone]

Hey Stu...some pics bro cos you got me all excited here........... :cool