i may not use this intake manifold, but i thought i might bore it out just incase i don't get around to building a new one before the engine is in the car.
setup on mill:


first setup the manifold so that the t/b mounting surface is flat, then indicate the port to find the center, or as close to center as you can get. the stock casting isn't perfectly round.

measurement before porting:

oem tb measurement:

replacement tb measurement:

comparision between the two... i will have to modify the replacement to add the map sensor on top. shouldn't be hard to do.


i couldn't fit a proper boring head in the limited travel of my mill, so i opted to use this small flycutter. here it is making the second cut. worked fine with the quill feed engaged.

finished dimesion (slightly larger than the tb):

as you can see the casting isn't exactly even all around so make sure you go deep enough to get all the material to make it a smooth transition.

 

Wow that looks amazing!

 

is this the S2K manifold aaron?

You don't NEED to mount the MAP sensor on the throttle body, all you have to do is run a vacuum line from the nipple on the throttle body to the MAP sensor (this is how pre 93 or 94 hondas were).

 

yes it is the s2k intake mani. i was thinking about just mounting the map on the manifold somewhere. that might not be easier, but it might look cleaner.

 

nicely done

 

PART 2: PREP FOR CHROMING

after welding, facing the tb surface, before boring:


after cleaning up the iacv ports. 70mm compared to 66mm


all taped up ready to be sand blasted:



here are some comparison pics...
oem:


smoothed:


blasted:


oem:


smoothed:


blasted:


comparison between the 70mm and 66mm after blasting:


before blasting:


after blasting:



oem:


smoothed and blasted:


ready to be chromed i say!