Info needed on porting details for a stock Tuned Port Intake manifold

[Daniel Burk]

I'm in the process of porting my intake manifold and was wondering if
anyone else has done this.  

So far I have about four to five hours worth of porting done on the
first of the eight ports.  I'll try to describe what I've done so far.

I've gasket matched the intake gasket area which involved grinding
substantial material away from around the roof of the port around the
injector boss.  There seemed to be a "lip" of some sort that I hope
wasn't an air deflector 'cause it's gone now.  The overall port size now
matches the gasket perfectly.

The runner gasket area was really weird: Kind of shaped like a trumpet,
so that the opening was already larger than the gasket, but necked down
to the gasket diameter over about a radius of 2 mm.  The gasket is a
perfect fit to the runner, which is smaller than the intake opening.  I
have opened up the port to the diameter of the intake opening to remove
the "trumpet" look.  Substantial material was ground out into the port
about 3cm.  

As the port proceeds towards the intake gasket area, it makes a rather
abrupt turn to straighten and turn into the cylinder head.  I've found
that the material in this area is a good .200" thickness, so I have
ground out about half, about .100" to increase the inside radius of the
turn.

Lastly, I have noted that about .200" material exists in the roof of the
port, so I have raised the roof of the port around the injector boss
about .050 - .100 ".  I have also lowered the floor of the port at the
runner entrance about .050" to .100" in order to again smooth the bend.  

Now I DID have one incident that scared me almost ot death:  I hit a
pore in the aluminum.  It made me think that I had perhaps ground into a
water jacket, but as I examined it, I decided to continue grinding.
(What the hell, I thought, I'll have to weld anyway if it's through.) 
Luckily, I ground the pore out and it stopped.  


Now, Has anyone attempted to port one of these things, and if so, do
these procedures sound like the right thing to do?  I don't have access
to a flow bench to test them, but would like feed back from experienced
porting people.

	Dan.