dmg210

Hi guys,



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



I want to make this





Match this







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



Cheers,

Dan

JonGTR

Just match the gasket and take a Dremel to it.

dmg210

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.

JonGTR

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.

dmg210

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/