i gasket matched all my intake and exhaust ports , and it made a big different , all i used to do this was a typlical cardide burrs to remove and form my ports,, really easy to do,, i also wanna note if you port your head do if off the car so you dont get shaving in your motor,, heres a link to what tools i used.

http://www.skspeed.com/images/catalog/CTC07403.jpg

i use my dremel with the snake adapter. with 1/8 shank carbide tips. i buy them from a local specialty tool store, but i have used ones from homedepot and they worked fine,

when it comes to polishing i use these cheap aluminized kawasaki ones i can burn up fast.. then hand sand with a fine grit.. for finishing touches

Carbidebur.com

Get a tree radius double cut carbide bur from there and a $10 die grinder from harbor freight. Pick up some cartridge rolls from harbor freight too for $6, and to really get a mirror finish find cross buffs online. There is tons of information on here and VFAQ on how to port.

With that stuff and an air compressor, you can port your exhaust manifold, O2 housing, turbo, and gasket match your intake ports to the head. If you don't have an air compressor, an electric die grinder is a cheaper choice and runs like $50 from harbor freight.

one_bad_7 said:

i use my dremel with the snake adapter. with 1/8 shank carbide tips.

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What's your completion time on a manifold or o2 housing, about 2-3 weeks?

I thought porting was time-consuming using a die grinder....you have to be there for a while with a dremel.

Go with the electric die grinder (Makita from Harbor Freight works great and is relatively cheap) unless you have a commercial air compressor, and don't waste your time with anything other than good double-cut carbide bits.

Also, dress appropriately (and not just eye protection). Porting sucks IMHO, although it's kind of fun in a masochistic kind of way. Metal slivers get EVERYWHERE...including places you won't think are possible. Your porting job will live with you a week or two after you think you've finished

calan said:

Go with the electric die grinder (Makita from Harbor Freight works great and is relatively cheap) unless you have a commercial air compressor, and don't waste your time with anything other than good double-cut carbide bits.

Also, dress appropriately (and not just eye protection). Porting sucks IMHO, although it's kind of fun in a masochistic kind of way. Metal slivers get EVERYWHERE...including places you won't think are possible. Your porting job will live with you a week or two after you think you've finished

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Those slivers are the devil. At least with cast iron or steel. Wear shoes and clean the whole house out a few times or you will get them in your feet by the dozen. And wear an apron you can dispose of and shoes that wont catch anything in them.

I would definitely start by porting the O2 housing. It will be pretty simple and let you get the hang of the work. Plus there is nothing downstream of it for residual metal chips to hurt.

This will sound dumb, but it worked for me:

Since my shoes, and therefore the skin of my feet, got filled with the little filings last time, I tried porting with just socks and flip flops. Throw the socks away when you're done, and blow off the flip flops.

Done.

I got my electric die grinder from harbor freight. It was $30. Compressed air is a waste of time.

I also got a double cut burr from Amazon.com of all places. It cut like mad, and was about $12.