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Join Date: Oct 2006
Location: MYR S.C.
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how thin on intake ports

my intake ports are already pretty thin.
how thin can you go.
I would like to port to 40mm

unless someone has an intake port for sale I am only going to about 36mm

40mm would be to the outside edge on the black line

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86 930 42kmiles [__] RUNNING:[__] NOT RUNNING: ____77 911S widebody: SOLD
88 BMW 325is 200K+ SOLD
05 BMW 330CI 130K:: [__] RUNNING: [__] NOT RUNNING:
08 VOLVO V70 190K:: [__] RUNNING: [__] NOT RUNNING:
90 B2200[__] RUNNING:[] NOT RUNNING:__2000 MER E320 WAGON [] WRECKED:[]RUNNING:
Old 04-12-2019, 06:43 AM
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Mine are 40mm with no issues
Old 04-12-2019, 06:50 AM
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I’m on my second manifold. Luckily I have three. I effed up on my first attempt at porting it out to 40 mm. I sent it out to be welded but the weld failed so I threw in the towel and started over.
My method is to bolt up one of my 40mm aluminum injector blocks to the manifold and drill about 3/4” with a 1-5/8” hole saw. Which is a perfect fit. Then I grind it roughly to shape with a 1/4” shanked straight metal bit and finish with a tapered stone that fits my 1/4” die grinder. I’ll post some pix when I get home from work.
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81 Pacific Blue 930 Euro coupe slicktop on a strict diet, Rarlyl8 headers, Blowzilla turbo, Tial waste gate, Full bay I/C, Home made center out exhaust, Leask WUR, MSD 6AL, PLX wideband
Wevo shifter, LSD. Next up, Cams, Heads and port work
Old 04-12-2019, 07:32 AM
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Crotchety Old Bastard
 
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I've ported them by hand so the contour could be skewed away from the thin wall. Because the "runners" are asymmetrical I don't think the contour has to be the exact same on all 6, just the same area. I smoothed the transition best I could anyway.

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RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 04-12-2019, 01:21 PM
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Thatís true. And exactly why Iím on intake #2. Also itís more like 3/8Ē not 3/4Ē with the hole saw. I also agree that if youíre not set up with the proper machinery itís probably better of done by hand the entire process. It takes longer but itís safer. The tolerances get skinny when going to 40mm.
The hole saw did itís job though



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81 Pacific Blue 930 Euro coupe slicktop on a strict diet, Rarlyl8 headers, Blowzilla turbo, Tial waste gate, Full bay I/C, Home made center out exhaust, Leask WUR, MSD 6AL, PLX wideband
Wevo shifter, LSD. Next up, Cams, Heads and port work
Old 04-12-2019, 04:58 PM
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At $10 a pop for the HF grinders I had to buy two.
I think I bought the Mr Pinky (Ronnieís favorite BTW) there as well but if so they no longer have it.
The other one is a lath and plaster cutter designed for a roto zip. Cheap and cuts magnesium like butter but be careful, they can get violent and do allot of damage in short amount of time.
I found moving the tool at the same direction the blade turns worked well at times.
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81 Pacific Blue 930 Euro coupe slicktop on a strict diet, Rarlyl8 headers, Blowzilla turbo, Tial waste gate, Full bay I/C, Home made center out exhaust, Leask WUR, MSD 6AL, PLX wideband
Wevo shifter, LSD. Next up, Cams, Heads and port work
Old 04-12-2019, 05:15 PM
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Crotchety Old Bastard
 
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Noteworthy point on how aggressive the bits are with air tools. I had better control with the variable speed drill. It is really tedious work but that's what you need to do if you want precise results.
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RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 04-12-2019, 07:54 PM
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Mighty Meatlocker Turbo
 
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Yo' 70'sBush, if you want more percision in your hand , set "Mr. Pinky" aside and buy one of these.

I shiit you not, it is a remarkable piece, and one of my most used tools (other than the other tool! ). Super slow to super fast speed that is easy to control and adjust (no trigger to hold down), and weighs almost nothing.

https://www.amazon.com/gp/product/B000RH36WU/ref=ppx_yo_dt_b_asin_title_o07_s01?ie=UTF8&psc=1



BTW, that plastic tubing is actually a muffler - you slip it over the end of the die grinder, where the air discharges, and it really quiets down the high pitched shriek of the thing.

PS - Brian is a masochistic caveman for using a drill for metal work like that - dayuuummmnnnn!!!!

Last edited by Rawknees'Turbo; 04-12-2019 at 09:13 PM..
Old 04-12-2019, 08:56 PM
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Crotchety Old Bastard
 
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Variable speed drill is for the fine work, air tool to do the bulk metal removal. The air tool I have is too aggressive to do the detail work. Need something just a little bigger than a dental drill. That gadget you posted looks like the ticket!
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RarlyL8 Motorsports / M&K Exhaust - 911/930 Exhaust Systems, Turbos, TiAL, CIS Mods/Rebuilds
'78 911SC Widebody, 930 engine, 915 Tranny, K27, SC Cams, RL8 Headers & GT3 Muffler. 350whp @ 0.75bar
Brian B. (256)536-9977 Service@MKExhaust Brian@RarlyL8
Old 04-13-2019, 06:15 AM
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Thanks Raw. You da man. I just placed my order. Gotta love Amazons one click shopping.
Although Mr. Pinky works really well itís good to have an arsenal.
Brianís point about the air tools canít be overstated. Although I canít see doing this with a drill, itís all about what tools work best for the individual user.
Another thing I found helpful for controlling Mr. Pinky is to put my finger between the grinder body the underside of the trigger. This prevents it from spinning at ten million revs per second. It also keeps the bit from loading up with magnesium.

BTW JFairman posted an excellent bit on porting his early turbo heads
that he used on his top end rebuild for his, now sold 87 930. For those who didnít fallow, he did that rebuild in his parking lot w/o pulling the motor. One of many of his amazing contributions to this forum. We miss you brother.
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81 Pacific Blue 930 Euro coupe slicktop on a strict diet, Rarlyl8 headers, Blowzilla turbo, Tial waste gate, Full bay I/C, Home made center out exhaust, Leask WUR, MSD 6AL, PLX wideband
Wevo shifter, LSD. Next up, Cams, Heads and port work
Old 04-13-2019, 12:23 PM
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anyone have an extra intake.

my walls are pretty thin already.
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86 930 42kmiles [__] RUNNING:[__] NOT RUNNING: ____77 911S widebody: SOLD
88 BMW 325is 200K+ SOLD
05 BMW 330CI 130K:: [__] RUNNING: [__] NOT RUNNING:
08 VOLVO V70 190K:: [__] RUNNING: [__] NOT RUNNING:
90 B2200[__] RUNNING:[] NOT RUNNING:__2000 MER E320 WAGON [] WRECKED:[]RUNNING:
Old 04-15-2019, 12:24 PM
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Have you already started? Why not got to 38mm (thats why I did). Unless you already have the injector blocks?
Alan
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83 SC, 82 930 (track) - Stock except for RarlyL8 race headers, RarlyL8 Zork, K27-7006, 22/28 T bars, 007 Fuel head, short 3&4 gears, NGK AFR, Greddy EBC (on the slippery slope), Wevo engine mounts, ERP rear camber adjust and mono balls, Tarret front monoball camber adjust, Elgin cams, 38mm ported heads, 964 IC. 380rwhp @ 0.8bar Apart from above, bone stock:-)
Old 04-16-2019, 11:03 AM
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not started anything yet other than tear down to inspect engine.

I still think 38 is too big for my intake.

if I can find a good intake for the right price I will get it, otherwise I am going 36mm.
I know there are a lot out there from EFI conversions and not many people want or need a 930 intake, so they should be pretty cheap. found one for 500, way too much IMO

i have about 14k budget on the motor and i would like to twin plug and get ignition unit also. trying to utilize my money as best i can.
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86 930 42kmiles [__] RUNNING:[__] NOT RUNNING: ____77 911S widebody: SOLD
88 BMW 325is 200K+ SOLD
05 BMW 330CI 130K:: [__] RUNNING: [__] NOT RUNNING:
08 VOLVO V70 190K:: [__] RUNNING: [__] NOT RUNNING:
90 B2200[__] RUNNING:[] NOT RUNNING:__2000 MER E320 WAGON [] WRECKED:[]RUNNING:
Old 04-17-2019, 06:22 AM
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