CincyScott

I started porting and polishing the heat exchangers today based on some input I received from Kevin (at UMW, of course). It's tedious work, but I'm just positive it'll yield hp gains beyond my wildest dreams! I'm only kidding, I've just got it all apart and it seemed like the right thing to do before I do any upgrades.

Passenger side exchanger has some nasty shrouding from the number 6 cylinder:



This is after I ground back the majority of the shroud



And a close up:



Not shown here is an appreciation for how ugly the exhaust side really is into the turbos...I was kinda stunned when I looked at. It won't be possible to smooth it completely out because there are some seams to deal with (I suppose you could weld them, but I'm not). Next step will be to get it progressively less gnarly til it shines

No idea if this is worth a ton, but I've got the tools and the time!

CincyScott

Next up is to also smooth the exhaust valve side as well. Here's a before and after of that. Again, hard to get an appreciation for how lumpy they are from the factory.

Before:



And after: Don't forget this is just the rough in!

Turbodan

looks good ! please let us know how much time this job takes...I feel too lazy to do this

CincyScott

My guess is that I'll have between 8 and 10 hours in it by the time I'm done. I just ordered new carbide bits which should speed the rough-in part considerably. I'll keep everyone posted!

Basal Skull

When I did this, I couldn't believe Porsche left those metal pieces sticking out. It has to be worth plenty of HP and earlier spool up to grind them down!

wagongotya

Nice have fun!

As a warning, be careful of the amount of metal you guys take away when porting...i've seen many exhaust manifolds ruined this way.

hal m

The photos I have seen from Extrude Hone seem pretty impressive. How would that be.

CincyScott

The fact that the heat exchangers are essentially tubular headers with large flanges on them makes me think Extrude-Hone wouldn't help much. If it were truly cast, I think it would work well.

Spartan

Nice work! I did this years ago and its withstood many track days and the manifolds hold up just fine (no cracks)

Kein_Ersatz

Thanks for sharing.

10 hours of skilled shop labor, $800.

The feeling of pride in a DIY job well done, priceless!

CincyScott

Finished this last weekend, and it was closer to 6 hours once I had sharp carbide bits for the rough in. Definitely glad I did it though, but I would have never tried it without Kevin's coaching!

This board really is an asset for the diy'er.