tehcarguy

I know how much you guys love pics.


But then this happened



The burr I was using galled up and this is how far I got



Obviously, I'm not using the right burr. Can you guys give me some suggestions on what to use?

Black89Z51

You can't use burrs for aluminum. You need to get a cutter made for aluminum. Word to the wise, it's going to be agressive and take a ton of metal fast. Be very careful and take small, light cuts. Anything like what you have there, which is made for steel, is going to fill up in a heartbeat.

Oh, and put it in a vice or something of the sort. You need both hands on the tool for the best control. If you are using one hand on the dremel and one hand on the plenum, it's a recipe for disaster and a trip to the ER. If you are just letting is sit there while you go at it, you're going to run the risk of it shooting off, and minimum ruining the plenum. And wear safety glasses if you aren't already.

AKS Racing

You can use these cutters for aluminum. Dip in ATF frequently, and the cutter will stay clean.

In your case, use a scribe to pull out the aluminum, and then dip in ATF and continue on with your porting.

cv67

as said get the piece secured via vise or Cclamp etc.

Dont need much speed at all otherwise youll burn up the bit,it will skip around, gouge etc.
All about control. Ill see if I got any laying around I could give up
If so Ill shoot you a pm and send it your way.

tehcarguy

Thanks cuisinartvette, I was hoping to hear from one of the best. That's not really necessary, I'm wanting to get this done so I can get it back on the road. (my dd is giving me some issues) Thank you very much for the kind offer though, just need a quick trip to the hardware store tomorrow. AKS, I'm not gonna use this burr anymore, even when it was clean when I first started it wasn't doing much.

Ricky 91 vette

Keep us posted, I have 58 bbk tb too , and when I took my plemnum to the machine shop they wanted $150 to ported so I just installed it like that, but I wanna do it myself soon, I just need to know which tool I should use, and how to smooth it

Dr.Huxtable

Speed is a very important factor. I've done alot of porting myself and speed will only develop heat, heat will clog up your bit and/or damage it. I use an air die grinder with a regulator that i turn way down, around 20 - 25 psi. The bit doesn't jump around, makes a nice clean cut. Metal will be flying.

Every couple min i'll spray on some wd-40 to the bit and surface. keeps things cool and lubricated. I find that this style of burrs work the best, just an example, i don't have this kit but all my bits are the same style:

http://www.google.com/imgres?imgurl=...t:429,r:20,s:0

Here's some recent work i've done on my miniram. Still needs the final smoothing but you get the idea. Some other pics of previous work too.

tehcarguy

Thanks for that info and pics dr huxtable. I noticed in your thread you just got a 58mm tb. What are you using in place of the stock intake tube?

Dr.Huxtable

i'll be using one of these pieces from the old motor that was in the car. This one is splitting and cracking on the underside though so i need to source out a new one somewhere.

383vett

I'm a WD40 guy too.

GREGGPENN

WD-40 or other cutting oils will also suffice. The main thing is to keep the burr from getting too hot.

I used a burr with a long shaft. And, for runner tube porting, I used an extension for my bits. Since I didn't have (and couldn't afford) to buy an air compressor, I bought a 2k rpm variable speed drill. It seemed about the right speed. The advantage of the longer shaft (and extension) is you can use a gloved hand to apply/control side pressure. With the correct speed/control, a burr is a great option for porting.

Here are the tools I used/tried...


To get this result (base was polished after picture was taken)...


Then, I continued further porting running and base...




Most of this was done with a drill and burr (as pictured). Some of the tube work was done with the long extension, wire wheels, and flap wheels.

Caboboy

Showoff

Seriously nice work Gregg, that gives me twig

Ricky 91 vette

After searching around I bought one foot of some tube from napa! It worked great with my 58 and after market cold air intake

radar502

Nice to somebody doing something besides just makeing a phone call.. Great job....

Dr.Huxtable

Whoring out some more pics of my progress This is still all the initial cuts with carbide bits. Then i'll move onto sanding rolls and cross buff kit for final smoothing

The 2 on the left are in the middle of being cut







The 2 on the right are in the middle of being cut

radar502

Thanks for the pic ..We love pic....

GREGGPENN

Good stuff Maynerd!

dclafleur

All the newer intakes are nylon composites. Are people porting them with just sanding rolls? I can't imagine that people have given up porting intakes just because the new ones are plastic.. The work looks good, I'll have to try my hand at it someday.