? about port matching
 

Hey guys,

New to this stuff, gonna take my time!

I would like to match the ports on my intake to the gasket (FelPro), and working with an Edelbrock Performer.
All I have at my disposal is a couple of Dremel's, and wands.

First, are these up to the task? Or do I need to get an electric die grinder? No room for a compressor and air powered die grinder. It's ok if it takes longer, just means I have less chance of really screwing it up, eh? :lolsmile:

Second, if it is, what kind of cutters and such should I get? Carbide burrs? Stones? Diamond?

I know that aluminum requires different ones than iron or other materials, just can't remember what goes to what!! Is there a website that I can go to for more info to learn about this?

I also realize that the rough cutting/grinding and finish work requires different parts, what is VB's recommendations?

Sorry for the newb questions, but this is the best place to learn, yes?

Any and all help is appreciated!

:cheers:
Paul

You'll want carbide burrs that have more space between the cutting edges for aluminum. I highly suggest using a cutting wax on the burrs to keep the aluminum from "welding" itself to the burrs.

I'll get some suggestions for burrs and cutting wax after Industrial Supply Equipment from MSC Industrial Supply is back up ( scheduled maintence on the tool supplier's website )

Are the die grinders and wands ( better ) 1/8" or 1/4" diameter ?

:seeya: Jeff

They are 1/8" collets.

Really looking forward to your suggestions! Thanks Jeff!

Bought quite a few things from MSC when I was in the fab shop at a previous job. Also worked with aluminum, but that was long ago, and nothing as big as what I'm planning now!

The wax, you just dip the burr into it before you start cutting into the alum? Then redip whenever it 'feels' like the burr is smoothing out? Or... ?

New to this stuff! Thanks again!

Paul

Here's the link for the wax page
Browse the MSC Big Book
The castrol on the bottom left is what I use at work.

Here's the page with the Dremel cutters
Browse the MSC Big Book

The carbide are twice the cost of the high speed steel but last longer. Since your project will only be once and done ( most likely ), I'd get a selection of high speed cutter.

Jeff

Thanks for the info Jeff! I appreciate it!

Gonna go poke around their site for a bit! Also McMaster-Carr and Global too!

:thumbs:

Paul

McMaster Carr shipping prices are higher than MSC. I also saw an abrasive porting kit ( hand drill ) in my Jegs catalog.

Jeff

If you are not experience with this, I would not recommend you use an aluminum burr. It will eat the aluminum very quickly in a die grinder and potentially harm your result. Aluminum burrs work with better control in an electric varible speed drill. For port matching and going slowly as you seem to wisely desire, use paper. You can use a variable speed 3/8ths chuck drill. Look at your home building supply, ACE Hardware and get the longest 1/4" shoulder bolt you can find. I mostly use one about 6 inches in length. Cut the hex head off and with a hacksaw cut a notch about 3/4 inch long in the threaded end. This is where you will slip in one end of a Emory paper strip you tear off a sheet. The drill will roll it for you with a little power applied. I use strips about 1 inch wide to cut into the aluminum ports. You can keep the paper from loading up with aluminum by spraying the material with WD40 or old transmission fluid. New trans fluid is cheap by the quart and way more than enough for your job. Start with coarse paper to get the shape and work down to finer grits as you get close to the desired port shape. Do not try to make the port smaller than the gasket opening, just blend it. Do not just round the port edges to the gasket shape. You need to blend the port back into the runner 2-3 inches. Using this method you will have less chance to mess up and with little cost, if you already have a hand drill. A Dremmel is too slow for this job and with not enough power and lacking tools with enough length to reach into the ports.

If you decide to buy aluminum burrs, Eastwood has an assortment of burrs, both for aluminum and iron, you can buy as a kit or individually. If you want pre-rolled paper, Harbor Freight has a kit that will work. I have ported and polished many heads and blocks with one of a few die grinders, Dremmel tools and from this experience I can recommend the method I have outlined in good conscience. Go slow, think everything through and you will get good results.

Thanks slingshot! Those are all great recommendations!

Kind of OBE right now since, in my hurry to just get the damn thing together, I put a different intake on it for now, but am still planning to do the other!

Will print out this thread and put it into my file for future reference!

:cheers:
Paul