Doing a port/polish job is not as difficult as people make it out to be. This article is by NO means, the be-all-and-end-all of port/polish jobs. This is a simple, step by step guide to a quick, but effective, DITY gasket match port job for the intake manifold. As with all maintenance there is an inherent risk involved, and all manuals should be read, and safety procedures followed. This is for your reference ONLY, neither DSMtuners.com, nor myself shall be held liable for any accidents that occur if you attempt this procedure.
Tools needed:
DREMMEL (or any brand of rotary tool) - I prefer one with variable speeds, and a flex drive attachment, as the grinding stones should be spun a LOT faster than the brushes, and the flex drive allows you to reach farther into the runners, and is easier to maneuver.
Grinding stones - these are used to remove the majority of the excess "stock" from the inside of the runner. Silicon carbide is what I use, but there are other types of stones, some polish cleaner, some wear slower, that is a personal preference...
Brushes - wire brushes, flat, and conical - used to remove dust/dirt/carbon buildup/metal flakes
sanding/polishing barrels (or disks or stones) - again personal preference is used here, as I know people that swear by felt pads with polishing compound, and others that say a wood sanding barrel is all that is needed. Experiment and find what works best for you.
Intake manifold - DUH!
Intake mani gasket - you can just clean off your old one, you SHOULD be replacing it anyway...
eye protection - I use an old pair of sun glasses
gloves -
paint pen, or something to mark the manifold with -
a few bolts that fit in the stud holes in the manifold -
