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Thread: Intake Porting

  1. #1
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    Intake Porting

    The port and polish work is done, next step is thermal coating and installation. The throttle body bores were opened up at a machine shop, then blended by hand with the rest of the surfaces of the upper intake manifold.



    Those surfaces looked so nice, I felt that I should deburr and hand polish the rest of the inside surfaces of the upper manifold.



    That's already more than I had planned to do, as I just wanted to match the throttle bores with my twin 62mm BBK throttle body. BUT, while the upper was at the machine shot the owner of the shop asks why I'm not doing the whole thing and do it "right" instead of half-way. So I searched for a reasonably priced, reputable source for porting the lower intake. I sent it to James Hensler of Hensler Racing Engines and they did this:



    That is all hand-worked, and they popped the freeze plugs out of the bottom to access the bottom side of the plenum and runners. They also port matched the ports to intake manifold gaskets, so whenever I decide to have head work done, I just need to have the heads port matched to the gaskets and everything is good.



    I wanted the intake to have a bleck finish like the rest of my engine, so it has to be coated before installation. I considered powder coating, but figured I might as well experiment with thermal coating to get some functionality along with the looks. Soon as it gets back, it'll go on and I'll post before/after dyno results.
    Thanks to Darrin @ BC Automotive:
    $1800 and it was worse than when he started!

    Brian (FordNut) FPG # 1458 of 7838
    03 MM 300A (Lotsa mods, 130k mi) was 303rwhp/318rwtq N/A
    then 476/410 D1SC ProCharged on stock block
    then 660/555 D1SC PC on 5.3 wet sleeved Teksid alum big bore stroker
    then 365/369 N/A on 5.3 wet sleeved Teksid alum big bore stroker
    Now 751/617 3.4L Whipple on 5.3 Boss5.0 iron big bore stroker

    03 MM 300B Silver (Mostly stock, originally wife's car, 370k mi) FPG # 7053 of 7838 or 49 of 417 SB
    03 MM 300B Silver, Stock, wife's next one, 136k mi FPG # 7134 of 7838 or 89 of 417 SB
    04 MM Silver, Stock, on standby 85k mi, FPG # 1212 of 3214 or 432 of 997 SB
    01 F150 longbed
    01 F150 shortbed
    00 F150 4x4 stepside
    01 F150 4x4 7700
    68 Stang FB (70 351C 4V, 4 wheel discs, project car)

    Mods listed here (some items not current): FordNut's Mods

  2. #2
    hitchhiker Guest
    Please let us know what the results of your porting work are!

    And, how much it costs.

    Thanks,

    David

  3. #3
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    Thumbs up Smoooth!

    Good work !

    Hoping you get some worthwhile results!
    Bradley G
    2004 Trilogy #93P 12.2@113 Built and stalled

  4. #4
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    Zack and I experimented with intake mods last year, but we didn't get performance results that would underwrite a larger project for us here. However, we did not take the path you have, and your effort is very promising. Personally, I find exploring new ideas for the Marauder as enjoyable as just driving it, half the fun of ownership for me has been building it. Looking good, best wishes. Keep s posted?

  5. #5
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    This was my plan before the Trilogy. Very good idea for a N/A or centrifical blown MM. Amazon got about 30HP out of this set up on a Mach 1 mustang.

    11.98 @ 115 mph
    "Comfort, Class and Hair on Fire Performance."

  6. #6
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    Quote Originally Posted by SergntMac
    Zack and I experimented with intake mods last year, but we didn't get performance results that would underwrite a larger project for us here. However, we did not take the path you have, and your effort is very promising. Personally, I find exploring new ideas for the Marauder as enjoyable as just driving it, half the fun of ownership for me has been building it. Looking good, best wishes. Keep s posted?
    Me too, the journey is half the fun. If it doesn't work out as planned, so be it. That's one thing that irritates me about people flaming ideas that they haven't even tried. Somebody has to be first, right?
    Thanks to Darrin @ BC Automotive:
    $1800 and it was worse than when he started!

    Brian (FordNut) FPG # 1458 of 7838
    03 MM 300A (Lotsa mods, 130k mi) was 303rwhp/318rwtq N/A
    then 476/410 D1SC ProCharged on stock block
    then 660/555 D1SC PC on 5.3 wet sleeved Teksid alum big bore stroker
    then 365/369 N/A on 5.3 wet sleeved Teksid alum big bore stroker
    Now 751/617 3.4L Whipple on 5.3 Boss5.0 iron big bore stroker

    03 MM 300B Silver (Mostly stock, originally wife's car, 370k mi) FPG # 7053 of 7838 or 49 of 417 SB
    03 MM 300B Silver, Stock, wife's next one, 136k mi FPG # 7134 of 7838 or 89 of 417 SB
    04 MM Silver, Stock, on standby 85k mi, FPG # 1212 of 3214 or 432 of 997 SB
    01 F150 longbed
    01 F150 shortbed
    00 F150 4x4 stepside
    01 F150 4x4 7700
    68 Stang FB (70 351C 4V, 4 wheel discs, project car)

    Mods listed here (some items not current): FordNut's Mods

  7. #7
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    Quote Originally Posted by FordNut
    Me too, the journey is half the fun. If it doesn't work out as planned, so be it. That's one thing that irritates me about people flaming ideas that they haven't even tried. Somebody has to be first, right?
    Brian, keep up the good work. I enjoy very much the write-ups from owners that try new things and are willing to experiment and blaze new trails. I find it the most interesting reading on this forum.

    You, and Cruztaker have cars and results that I admire very much. You have taught us that our little 281's have great potential and without going into the engine you have achieved remarkable results that on any given day can give a S/C MM a run for his money.

    Keep up the good work. Thanks.
    Last edited by Smokie; 04-19-2005 at 04:22 PM.
    Smokie
    12.79 @ 107 mph.
    60' 1.851 Street tires & Stock wheels.
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    Performance Mods: Base Trilogy Kit, Exhaust, PHP Airbox.
    Visit my Garage
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  8. #8
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    That looks great! The machine shop did a really nice job hand porting your intake. It's also good that they didn't have to 'section' it and then re-weld it together after porting.
    It looks like they did not open up the ports too much, so the intake's ports will match up well with the cylinder heads.

    The upper/lid looks sweet! I had my upper powdercoated, and the powdercoat guy suggested that he do the inside of the lid as well...
    The inside came out smooth and glossy, which works great because when they Extrude Honed my intake they only do the lower portion.

    I spent last night port matching my cylinder heads so that they will match my Extrude Honed intake ports.
    I had to do this because the Extrude Hone process made the intake's ports BIGGER than the cylinder head's ports.
    This resulted in a sharp 'lip' sticking out into the airflow's path. (mainly on the outside edges near the injector port.)
    I had to modify both the OEM hard plastic gaskets and the first 1/2" of the cylinder head's ports.
    After a few hours with my trusty Dremel and a sore back, I had blended the ports nicely.
    I spent the first part of the evening blocking off the cylinder head ports to preclude any aluminum shavings from falling down into the ports/combustion chambers.
    Do you know funny it looks to be carefully vacuuming your cylinder heads???
    I am confident that the reduction in airflow turbulence will result in the Extrude Hone intake performing to it's fullest potential.

    Now I've got to call PHP and order an intake spacer kit!
    Last edited by Joe Walsh; 04-19-2005 at 02:59 PM. Reason: change
    2020 Ford Ranger STX DFI Turbo 2.3L 10 speed Auto
    2017 Ford Fusion Sport DFI Twin Turbo 2.7L V6 6 speed Auto (14.000 ET bone stock in 82 degree heat)
    1985 Mustang GT 5.0 Hatchback 4bbl 5 speed manual (525 HP 363 Dart block/AFR heads with Magnum 6 speed in the works)
    1984 Mustang GT 2.3 Turbo Convertible FI. 5 speed manual
    1966 427 Cobra (ERA) 468 all Aluminum FE 2x4bbl 5 speed manual

    SOLD : 2003 Mercury Marauder FI. 4 speed Auto
    w/Crower Cams & Springs, +1mm SS valves, mild port job on the cylinder heads.
    Extrude honed intake w/PHP spacer.
    Kooks Headers w/2.5" High Flow Cats & X-Pipe, Magnaflow mufflers, OEM tailpipes w/Megs Tips
    B&M Trans cooler w/fan, Level 10 Shift Kit, Art Carr Hughes Deep Sump Trans Pan,
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    Built: 10/15/02 Bought: 12/16/02 Sold: 10/15/18

  9. #9
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    Pics of the thermal coated manifold:


    Bottom:

    Thanks to Darrin @ BC Automotive:
    $1800 and it was worse than when he started!

    Brian (FordNut) FPG # 1458 of 7838
    03 MM 300A (Lotsa mods, 130k mi) was 303rwhp/318rwtq N/A
    then 476/410 D1SC ProCharged on stock block
    then 660/555 D1SC PC on 5.3 wet sleeved Teksid alum big bore stroker
    then 365/369 N/A on 5.3 wet sleeved Teksid alum big bore stroker
    Now 751/617 3.4L Whipple on 5.3 Boss5.0 iron big bore stroker

    03 MM 300B Silver (Mostly stock, originally wife's car, 370k mi) FPG # 7053 of 7838 or 49 of 417 SB
    03 MM 300B Silver, Stock, wife's next one, 136k mi FPG # 7134 of 7838 or 89 of 417 SB
    04 MM Silver, Stock, on standby 85k mi, FPG # 1212 of 3214 or 432 of 997 SB
    01 F150 longbed
    01 F150 shortbed
    00 F150 4x4 stepside
    01 F150 4x4 7700
    68 Stang FB (70 351C 4V, 4 wheel discs, project car)

    Mods listed here (some items not current): FordNut's Mods

  10. #10
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    You have an email FordNut.
    2003A Mercury Marauder. Sold it, miss it.

    USMC 06-10-96 to 06-21-06. AH-1W and UH-1N!!!! OORAH!!

  11. #11
    Quote Originally Posted by FordNut
    Pics of the thermal coated manifold:


    Bottom:


    looks great man! I can't wait to see it installed!!!!

  12. #12
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    Thumbs up Sweet!!

    Quote Originally Posted by FordNut
    Me too, the journey is half the fun. If it doesn't work out as planned, so be it. That's one thing that irritates me about people flaming ideas that they haven't even tried. Somebody has to be first, right?
    Looking good 'Nut, and thanks for being the first to try this.
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  13. #13
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    Haven't had the time to hunt down the pics in the gallery to fix this thread, but I dropped the car off today for the intake swap this weekend. Scott strapped it to the dyno for a "before" pull today, and did I ever get a surprise. It's making more power now than it ever has. I sure hope the intake swap gives em a little more!

    Previous best was 303.0, running race gas and a race tune, Steeda underdrive crank pulley, 6-rib belt. Today it pulled 303.6 on premium pump gas and a street tune, standard size crank pulley, 8-rib belt.

    Hope to have more data by Monday.
    Thanks to Darrin @ BC Automotive:
    $1800 and it was worse than when he started!

    Brian (FordNut) FPG # 1458 of 7838
    03 MM 300A (Lotsa mods, 130k mi) was 303rwhp/318rwtq N/A
    then 476/410 D1SC ProCharged on stock block
    then 660/555 D1SC PC on 5.3 wet sleeved Teksid alum big bore stroker
    then 365/369 N/A on 5.3 wet sleeved Teksid alum big bore stroker
    Now 751/617 3.4L Whipple on 5.3 Boss5.0 iron big bore stroker

    03 MM 300B Silver (Mostly stock, originally wife's car, 370k mi) FPG # 7053 of 7838 or 49 of 417 SB
    03 MM 300B Silver, Stock, wife's next one, 136k mi FPG # 7134 of 7838 or 89 of 417 SB
    04 MM Silver, Stock, on standby 85k mi, FPG # 1212 of 3214 or 432 of 997 SB
    01 F150 longbed
    01 F150 shortbed
    00 F150 4x4 stepside
    01 F150 4x4 7700
    68 Stang FB (70 351C 4V, 4 wheel discs, project car)

    Mods listed here (some items not current): FordNut's Mods

  14. #14
    Join Date
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    Near Knoxville TN
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    Data from intake install:

    Dyno pull after ported intake installation indicates no change in hp or torque at the peaks. Actually, no change from about 5k up. However, it picked up about 50 ft-lb of torque from 3k-5k. At about 3500 it was putting our 275 ft-lb. The AFR was not affected. This pull was just like the "before" pull, just strap it on and run it. No tc lockup program, no tuning, etc. I wonder what it will do with a new tune?

    I'll try to get some pics up after while.
    Thanks to Darrin @ BC Automotive:
    $1800 and it was worse than when he started!

    Brian (FordNut) FPG # 1458 of 7838
    03 MM 300A (Lotsa mods, 130k mi) was 303rwhp/318rwtq N/A
    then 476/410 D1SC ProCharged on stock block
    then 660/555 D1SC PC on 5.3 wet sleeved Teksid alum big bore stroker
    then 365/369 N/A on 5.3 wet sleeved Teksid alum big bore stroker
    Now 751/617 3.4L Whipple on 5.3 Boss5.0 iron big bore stroker

    03 MM 300B Silver (Mostly stock, originally wife's car, 370k mi) FPG # 7053 of 7838 or 49 of 417 SB
    03 MM 300B Silver, Stock, wife's next one, 136k mi FPG # 7134 of 7838 or 89 of 417 SB
    04 MM Silver, Stock, on standby 85k mi, FPG # 1212 of 3214 or 432 of 997 SB
    01 F150 longbed
    01 F150 shortbed
    00 F150 4x4 stepside
    01 F150 4x4 7700
    68 Stang FB (70 351C 4V, 4 wheel discs, project car)

    Mods listed here (some items not current): FordNut's Mods

  15. #15
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    Thumbs up

    Quote Originally Posted by FordNut
    Data from intake install:

    Dyno pull after ported intake installation indicates no change in hp or torque at the peaks. Actually, no change from about 5k up. However, it picked up about 50 ft-lb of torque from 3k-5k. At about 3500 it was putting our 275 ft-lb. The AFR was not affected. This pull was just like the "before" pull, just strap it on and run it. No tc lockup program, no tuning, etc. I wonder what it will do with a new tune?

    I'll try to get some pics up after while.
    Make sure you call Alisha so you can get that phenolic spacer as well. I like the sounds of your progress, 50 ft-lb 3-5k is great, and it a great target area for TRQ.
    2003A Mercury Marauder. Sold it, miss it.

    USMC 06-10-96 to 06-21-06. AH-1W and UH-1N!!!! OORAH!!

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