How to bore intake manifold?
 

Hi guys,



How would you go about enlarging an intake manifold - throttle body bore with hand tools?



I want to make this

http://i1069.photobucket.com/albums/...psisoj9t4z.jpg



Match this

http://i1069.photobucket.com/albums/...ps0400sscz.jpg

http://i1069.photobucket.com/albums/...pswlbbxilx.jpg



The new throttle body is around 1cm larger that stock.



Cheers,

Dan

Just match the gasket and take a Dremel to it.

I'm not going to be able to make a perfectly round hole with the dremel through. I need to shave off about 1cm all the way round the intake manifold circumference. I was thinking of using something like a cylinder honing tool but sanding off like centimeter of material will take for ever lol.

You don't have to worry about it being perfectly round. The IM flange is just a mounting surface for the throttle body. As long as it's larger than the throttle body's port/gasket, then you won't encounter any airflow issues.

Fair point, well I'm going to give it a go at the weekend so hopefully all will go as planned. Whilst I'm at it I was thinking of gasket matching the intake runners... are there any risks to be aware of other than taking away to much material?



I have also have a phenolic spacer to install when putting it all back together. It came with 1x stock hyundai gasket so should I sandwich the spacer between 2 oem gaskets? The spacer is made of a plastic material:



http://www.sharkracing.com/03-08-tib...intake-spacer/