Matching Inlet Ports

[nova ian]

I am going to be doing some work on my 2ltr XE Head soon to open out the inlet ports to match them perfectly to my R1 Carb inlet manifold. Shown below

http://img.photobucket.com/albums/v314/cruisindude/nova/Image003.jpg

Obviously I need to get rid of that step so as the fuel/air can flow nicely. Could anyone give me any pointers on what to use for this, I was looking at one of these Die Grinders:

http://www.machinemart.co.uk/shop/product/details/cat36b-air-die-grinder-set

Would the stones supplied be the right thing to use to do the job in hand? or would they maybe to harsh?

Also while I'm at it is there anything else worth doing to the head that can be done by an amateur like myself!! Pics would be great if anyone has any!

Finally I need to smooth out the surface within the manifold too (See pic below), would using the above die grinder be the tool for this job aswell or is there a different method/tool that could be used?

http://img.photobucket.com/albums/v314/cruisindude/nova/Inlet_04.jpg

Thanks in advance for any help or advice
Ian:thumb:

[Welsh Dan]

I can't help you with the die grinders, but I've read in a few places that the texture on the inside of an inlet manifold helps to keep the fuel suspended properly.

[nova ian]

I can't help you with the die grinders, but I've read in a few places that the texture on the inside of an inlet manifold helps to keep the fuel suspended properly.

So does smoothing out the inside of the inlet not give any gains then? I was always led to believe that the smoother you can make the flow the better, but this is why i'm asking advice to try and find out whats what as i'm completley new to this:)

[philip]

heres some pics of heads ive done, should be able to se the finishes.

want inlets slightly rougher. exhaust mega smooth. also need to get a set of york cartridge rolls...www.cromwells.co.uk (http://www.cromwells.co.uk) search for york i suggest the 122 piece set;)
these first ones are for XE im building for mine at moment.
http://i59.photobucket.com/albums/g312/philbug/IMGP1753.jpg
http://i59.photobucket.com/albums/g312/philbug/IMGP1750.jpg
http://i59.photobucket.com/albums/g312/philbug/IMGP1751.jpg



c16xe:

http://i59.photobucket.com/albums/g312/philbug/DSC00396.jpg
http://i59.photobucket.com/albums/g312/philbug/DSC00375.jpg
http://i59.photobucket.com/albums/g312/philbug/DSC00394.jpg

think rover 220 turbo


another xe
http://i59.photobucket.com/albums/g312/philbug/DSC00240.jpg
http://i59.photobucket.com/albums/g312/philbug/DSC00236.jpg

'k' series'



cossie head, can sort of see the roughness on the inlets
http://i59.photobucket.com/albums/g312/philbug/2007-03-03012.jpg
http://i59.photobucket.com/albums/g312/philbug/2007-03-03009.jpg
http://i59.photobucket.com/albums/g312/philbug/2007-03-03006.jpg


mates xe made 180 on mantzel and chip:
http://i59.photobucket.com/albums/g312/philbug/DSC00502.jpg
http://i59.photobucket.com/albums/g312/philbug/DSC00501.jpg
http://i59.photobucket.com/albums/g312/philbug/DSC00499.jpg

alot harder to port with guides stil in, but didnt want them out so hard to make do.

[matt_vaughan]

The rough surface of the inlet manifold helps with the atomisation of the fuel, best to leave it rough imo.

I've never done any work like this though so cant speak from experience.

[nova ian]

Well they say you learn something new everyday!!:)

Wow big thanks for the info and pics Phillip:thumb: Top stuff.

This sounds abit of a daft question, but i'm going to ask regardless!! How do you create a smoother and rougher surface for the inlet and exhaust ports??

Thanks people

[Welsh Dan]

Use a rough stone for the inlet, and finish with smoother and smoother ones for the exhaust.

[Adam]

Leave the inlets about 80grit. You want it smooth(no bumps etc), but rough if you get me.
Like Phils pic
http://i59.photobucket.com/albums/g312/philbug/IMGP1753.jpg
If you compare that pic to your std xe inlets you will also notice that the port splitter has been ground down to a sharp edge. As std its like a wedge in the middle of the port.
The exhausts can be mirror polished.


As with sanding anything, just start with very rough paper/stones, and work your way down. You dont need to take big amounts out the port.
If you run your finger down the xe ports, you will a feel a lot of cast marks(ridges/bumps etc in the port), these are what your wanting to remove/flatten until its 100% smooth and even.
Concentrate on the top wall of the ports as thats where a lot of the gains are had from as its where the gas flows past as its pulled in/pushed out out the cylinders.

[nova ian]

Cheers Adam:thumb:

What sort of tools shall I use?? Can you use wet and dry or emery cloth?? I have one of them Draper dremmel multi tool style things, but its abit chunky and you can't get right into the ports with it.

Are you doing any work on your xe head??

[Adam]

I was going to mate,but with mine staying on the std inlet etc i haven't bothered. If i had carbs/bodies i definently would.

Yeah wet and dry/emery cloth is fine, but to first get them smoothish you will need something like cartridge rolls/stones, the type you get with dremels etc

[philip]

stones are a waist imo. get on www.cromwells.com (http://www.cromwells.com) buy the 122 piece cartridge roll set and a die grinder and go from there.


the rougher finish on the inlet can be made by using a rough cartridge roll, and evenly running it round the port...always keep it even to keep shape.


the exhaust 2 wyas ive found.....

1. easist thing to make...6mm round bar with a 20mm slot in the top, and some emery roll wrapped around to make a flap wheel.....can wrap round as many times to get size....just have a play, you'll know when trying what i mean.

2. if can find them get a small flap wheel...used ones are usually better as there worn, and not as co****, so would finish the port very smooth


use like an oil or other lubricant to help with the polishing.



o and when you do them as LLTN have said, just think about the way the head is bolted down and the way the gases flow as to where to remove material, smooth etc

[burgo]

mini flap wheels is where its at ;)

http://shop.ebay.co.uk/?_from=R40&_trksid=m38.l1313&_nkw=dremel+flap+wheel

the 80 grit flap wheel leaves the perfect surface imo

[nova ian]

Cheers guys:thumb:

So to clarify... 80 grit flapper wheel will leave a good enough finished surface for the inlets (Cheers for the link Burgo)

what grit would you use to finish the exhaust side? or do i just keep going down grits say 600 through 1200??

Also what grit gor actually opening them out or will the 80 grit be sufficient

Big thanks again for all the input:thumb:

[philip]

on that you can use the cartridge rolls to open it out, otherwise, get a metal burr, just be carefull as they will chew alloy like theres no tomorrow if not carefull......use the burr to rough out..e.g. take out most of the material til almost matched, then finish off with the cartridge rolls....but like ive mentioned, best way to get a good even finish(and also look good:cool: ) is make a flap wheel with a piece of 6mm round bar with a slot in, and wrap a peice of emery roll around it, and use with some lubricant, will finish the exhaust nicely:thumb:

[burgo]

ive got one of these bad boys for shaping the ports

http://cgi.ebay.co.uk/Tungsten-Carbide-Burr-10mm-No-6-Ball-Nose_W0QQitemZ360088269470QQcmdZViewItem?hash=item 360088269470&_trkparms=72%3A12|39%3A1|66%3A2|65%3A12|240%3A1318&_trksid=p3286.c0.m14 (http://cgi.ebay.co.uk/Tungsten-Carbide-Burr-10mm-No-6-Ball-Nose_W0QQitemZ360088269470QQcmdZViewItem?hash=item 360088269470&_trkparms=72%3A12%7C39%3A1%7C66%3A2%7C65%3A12%7C24 0%3A1318&_trksid=p3286.c0.m14)

i wouldnt recommend you try that tho lol, it removes the material extremely quick

[Adam]

Just keep sanding the exhaust ports with finer and finer grades to get it to a shiny finish(like you wouild when polishing anything)

[nova ian]

I'll get the Mr Sheen out thenlol

Cheers peeps:thumb: