My 2002 Magnum progress log (lots-o-pics, 56k?)

03blackrt · Post by **03blackrt** » Thu Aug 23, 2007 10:29 pm

Here’s my progress log for my porting project, it should start Monday [8/27].

The plans…

A] Porting

- Intake Manifold-
1) Match plenum/runner ports to OEM gasket.
2) Remove injector humps. Depressions will be filled with aluminum.
3) Enlarge intake manifold ports at flange.

- Cylinder Head-
1) Enlarge and smooth intake ports.
2) Smooth intake port bowls.
3) Smooth intake valve throats.
4) Smooth combustion chambers.
5) Smooth exhaust valve throats.
6) Smooth exhaust port bowls.
7) Enlarge and smooth exhaust ports.

- Exhaust Header-
1) Clean-up excess material inside header flange.

B] Cylinder head milled 0.040”.

C] Install COMP 400 camshaft.

D] New timing belt. If tensioner is hydraulic, replace with new mechanical tensioner. Check water pump condition.

E] New head gasket.

Stay tuned for progress photos.

kc2005ptgt · Post by **kc2005ptgt** » Thu Aug 23, 2007 10:34 pm

did you get your hands on a used mag head or something or do you have time to keep your car down? Thats awesome!!! I am gonna get my head ported and polished one day, just cant afford down time right now

Oh yeah, and that pricey P&P job

03blackrt · Post by **03blackrt** » Thu Aug 23, 2007 11:23 pm

I have a little time that I can have my car down. I am aming to take one week, but have allowed two weeks incase of problems.

03blackrt · Post by **03blackrt** » Sun Aug 26, 2007 11:50 pm

1) Removed the intake manifold.
2) Shaved the extra length of screw that attaches the MTV''s to the MTV control shaft.
3) Profiled (chamfered the edges) of the MTV's.
4) Feathered in the leading edge of the ram pipe.
5) Started gasket (plenum/runner gasket) matching ports on runner side of the intake manifold.

My tool of choice is a Matco pneumatic grinder with carbide bit. I have yet to receive some porting supplies from Summit, so the porting is not very straight and even.

anomalous0 · Post by **anomalous0** » Mon Aug 27, 2007 7:18 pm

neat! I'm doing the same project with my intake manifold at the moment. Using an electric drill and some grindstones so it's going a little slower but that will allow me to hopefully do a pretty even job. Is it just me or does the runner closest to the driver's side seem to get pretty much boned as far as airflow goes? Both from the plenum into the MTV (where there's that hump under it) and from the runner side as well, where it narrows down before it needs to?
It also seems to be where I need to do the most gasket matching

03blackrt · Post by **03blackrt** » Mon Aug 27, 2007 9:03 pm

Yeah, cylinder #4 kinda gets screwed by that hump.

1) Finished rough grinding all ports on the intake manifold. (20 holes in all

)
2) Started finishing ports with a hand rasp. I'm still waiting for some sanding cartridges from Summit, they should come tomorrow.

03blackrt · Post by **03blackrt** » Tue Aug 28, 2007 6:49 pm

- Finished the intake manifold
- Removed header and ported it.

atom · Post by **atom** » Tue Aug 28, 2007 7:39 pm

Looking great man! Any plans for a longtube in the future?

03blackrt · Post by **03blackrt** » Tue Aug 28, 2007 9:53 pm

I already have a longtube (the one in the pics)

03blackrt · Post by **03blackrt** » Wed Aug 29, 2007 10:41 pm

I did a little more tonight...

- I decided to make the intake ports larger

- Removed the head and started cleanibg the cc's.

kc2005ptgt · Post by **kc2005ptgt** » Wed Aug 29, 2007 11:53 pm

Thats what I want to do, but I think I will take it to a shop to have my head P&P'd... After that I wanna do the intake as well, and put on a 60mm (opening) pipe on the intake for a match to the CAI and TB. Nice job man, looking gut!

03blackrt · Post by **03blackrt** » Thu Aug 30, 2007 12:02 am

My next project will be to mod the intake for a 75mm Mustang TB... cause overkill is my middle name

anomalous0 · Post by **anomalous0** » Thu Aug 30, 2007 3:59 pm

are you going to polish the combustion chambers and round out the tiny lip that leads to the "mini quench area" to discourage hot spots?
Since we're working with overkill, after all, that's supposed to suppress detonation enough that you can run pretty high compression on pump gas.

03blackrt · Post by **03blackrt** » Thu Aug 30, 2007 6:00 pm

The cc's will be slightly cleaned up and polished.

- The head exhaust ports have been opened up to 1.5".
- Head intake ports have been opened up.
- The head has been milled 0.030" for ~10.5:1 compression, I decied to play it safe and not get it 0.040".

^Some tard put a casting number INSIDE the exhaust port

quicksilvr · Post by **quicksilvr** » Thu Aug 30, 2007 8:34 pm

Looking great! What'd you use to clean up the cc's? I'm refering to just the actually cleaning...not the polishing. Or did you just start polishing?

03blackrt · Post by **03blackrt** » Thu Aug 30, 2007 10:55 pm

^ I just started with polish and a crossbuff wheel.

More pics... all finished except for a little more polishing. Should be put back togather on Saturday.

03blackrt · Post by **03blackrt** » Fri Aug 31, 2007 10:15 pm

Tonight I cleaned the carbon buildup off the pistons using a flat paint scraper, carb cleaner and aluminum polish.

Everything is ready to go back togather

03blackrt · Post by **03blackrt** » Sat Sep 01, 2007 7:35 pm

She's done! $\:D/$

Kevin_GP · Post by **Kevin_GP** » Sat Sep 01, 2007 7:43 pm

Sweet man, notice any improvements? I would be nervous porting my head, but it looks like you did a great job.

03blackrt · Post by **03blackrt** » Sat Sep 01, 2007 7:50 pm

Ya, she definitly pulls harder in the topend. Porting it wasn't too difficult. But I would like to get my hands on a spare head and spend alot of time on it. This was just a quickey p&p... and my first attemp. I learned alot doing it.

Definitly the best mod I've ever done.

Before and after of the intake ports

EDIT:

I finally got around to measuring (via CAD) some photos I took of my porting to get the change in cross-section area from stock to ported at the flanges.

Specs:

Stock intake port area = 1.41 in^2 , 4.42 in circumference
Gasket matched intake port area = 1.79 in^2, 5.11 in circumference
Enlarged intake port area = 1.97 in^2 , 5.41 in circumference

Stock exhaust port area = 1.48 in^2, 4.32 in circumference
Enlarged exhaust port area = 1.77 in^2, 4.71 in circumference

soul_sword34 · Post by **soul_sword34** » Mon Sep 10, 2007 11:43 pm

03blackrt · Post by **03blackrt** » Mon Sep 10, 2007 11:53 pm

My photobucket account went down

03blackrt · Post by **03blackrt** » Wed Sep 26, 2007 11:51 pm

Bump.... I'm slowly rehosting some of the photos.

Next weekend I'm going to be taking the manifold off again and filling the injector depressions and grinding away the humps inside.

03blackrt · Post by **03blackrt** » Mon Oct 01, 2007 7:09 pm

Update! Well, I took off the intake manifold again to start filling the injector depressions... but got sidetracked. I decided I should go-for-broke and make the ports larger

They are now matched to the inside dimensions or the runners! The pics kinda tell the story... and I STILL have to fill the injector depressions. I also match ithe head ports to the manifold while the head was still on the car, something I dont recommend doing unless you like taking risks

Edit: more pics...

^enlargerd port compared to OEM gasket

^ not much left of the OEM gasket after making room for larger ports

EDIT: Pics of half-shaft mod and new throttle plate (made from resonator material!)

anomalous0 · Post by **anomalous0** » Tue Oct 02, 2007 4:28 pm

damn dude. You got skills AND balls.
I found one thing that really helped keep the aluminum shavings all in one place was to spray it down with WD40 every 20 seconds or so. Also helped unclog the grindstone. You're gonna LOVE the mustang TB with this. Make sure you get rid of the restrictive inlet. I just cut it off but I'll bet you could come up with something cooler like grinding a lip into it so that it clamps down better.

03blackrt · Post by **03blackrt** » Tue Oct 02, 2007 11:12 pm

I'll give the wd40 a try next time, my cutting bit always gets clogged! But I always thought the oil would cause too big of a mess to try it. There's nothing more fun than having a ton of alkuminum shavings spraying all over and in your face. Work is on hold untill I get a new grinder, I broke mine

I'll be mounting the tb directly to the manifold using an aluminum plate. I'll make a cut so the tb faces at a downsward 45 degreeish angle, eliminating the restrication.

anomalous0 · Post by **anomalous0** » Wed Oct 03, 2007 5:05 pm

The oil actually reduces the mess, keeps all of the aluminum filings in a sort of paste that you just wipe off with a paper towel or cloth.
Yeah, it will still get spattered around a bit, but not as much, and you don't have to wear a mask because none of it goes airborne

03blackrt · Post by **03blackrt** » Thu Oct 04, 2007 12:51 pm

So I fixed my grinder last night and finished up the ports... the original port job was completly enlarged somewhat. I still have to work deeper inside the throat, but can't really do that with the head sill on

If I only had these ideas when the head was off and I was doing the original port job!

I think this will do for my DD. She pulls stronger too, definitly could use a higher rev limiter.

Post by **Canada** » Fri Oct 05, 2007 10:55 am

Damn Man!

Looking Killer.

If you ever come to Canada on vacation, plan a few days at my place and I'll put you up so you can help me do this to mine!

Really great job!

jmr · Post by **jmr** » Sat Oct 06, 2007 12:12 am

Wow that is really going to breath. Yours probably outflows the old W-2 heads on the LA engines.