Now thats its winter, I am looking for a nice little project to start on.
I have a 98 F150 with a 4.6, that has the aluminum intake manifold.

I was thinking of maybe getting a manifold to polish up, as best I can, and then maybe smooth out the inards and maybe try to match the outlets to gaskets.

Has any one done this? What were your results? Oh, and does anyone have an aluminum manifold along with plenum they want to get rid of?

 

youll net about 10rwhp from it

 

I have matched and polished one. It is very time consuming work, but I really enjoy it.
The challenge with the 4.6 intake is the tight turns at the top of the intake. I could not find anything that would flex enough to make it around the tight inside corners.

 

I was able to get most of the turn, but man, I went thru about twenty cheap flexing extensions. At-least two per chamber - The ends would bust off at the hair pin

 

Yes, I know what you mean. I have another one I'm going to start soon, and I know there must be something better to make the hair pin corners. Some one suggested a " ball mill "??

 

Did you guys use an electric drill? I have an electric drill and a Dremel. Just have not got around to getting the extensions and what not.
Where did you get them?

 

Mine were Dewalt or Black & Decker (Same company) - I 'm pretty sure they had the B&D on the package. I had to make a custom shank to fit the 5 or 6 six sided receiver in the flex extension. The shank had a headless allen screw to tighten whatever bit you were using.

The flex extentions I used were found at Home Depot. Their weak and can't take much torque. I just sanded and polished myself. I used everything in the arsonal. - From a Die Grinder to an Milwaukee electric drill motor. I tried a Makita with a torque clutch on the corners - It was better, but you need the RPMs to be successful.

They don't make a tool that will worm it's way thru there no problem. I don't know of one anyway.

 

there is a company called extrudehone that forces an abrasive paste throughthe intake passages for optimum polishing- of course it costs

 

I use a die grinder with an air cheater to lower the rpm. Mine is the typical Home Depot variety. I have a dremel, but I only use it for detailing the small spots.

The extrude hone runs around $ 800 for one of these!

 

What was that website you gave me that one time, I can't find it

The the one that sold grinding,prep and surfacing bits. You remember?

 

http://www.sa-motorsports.com/diyport.aspx

Try googling - - - diy + port and polish....lots of articles, posts, etc.

It helps if you can find someone local to you to buy the abrasive rolls and other goodies, I buy from an industrial abrasives shop just down the street from me.

 

HI!... Been there, done that, like 6 years ago. lol!

 

HI!... You can also do the lower ABS plenum, TB ELBOW and the TB.

 

 

Looks awesome!