2.3T intake optimization

[RoninWolf]

So you are shooting for 400hp, on a budget...good luck

On merkurencyclopedia.com, there is a write up on intake mods. The #2 and #3 runner have a choke point, just under the injectors. It is recommended the 'dents' just under the injectors be welded up, to give you a safe amount of material, to cut away. It is also recommended, to weld up the underside 'dents', so you can open the ports up to pass a golf ball through (~1.60" diameter)...but at that point you are shooting for 500hp. I want to maintain air velocity for street ability at 400hp, so the relative stock port sizes (~1.50" diameter) will do.

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Tools
-1/2" chuck drill
-1/2" chuck x 40" flex shaft [Harbor Freight use to sell these, but had to buy one for $20 on eBay]
-sanding roll kit, from Harbor Freight
-1/2"oval carbide burr, "6 shank [had to buy online]
-1.5" to 1.6" hone [ask any mass production machine shop, if they have any used hones you could have. Or ask where they take their scrap to ]

[RoninWolf]

#1 and #4 are very easy to clean. Smooth out the transition, around the injectors area, cut any casting lines up the port, and hone the port with a bit of your favorite gear oil.

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#2 and #3 are the challenge. If this is your first time porting, I would stick with a 6" shank. It gives you less leverage, aka less opportunity to mess up. It will take more time to do, but minimize the risk of slipping up....maybe cut an inch off.
I removed the hump, to a thickness of ~1/16" around the injector port. The inside edge, near the coolant passage can be cut back a bit, remove casting lines up the port.
Little gear oil and hone.

THE INITIAL OPENING HAS NOT BEEN TAMPERED WITH...at least not yet. I seriously need to flow bench the full assembly (throttle body : no plate, upper 90 degree rotated : not gutted), to do any other mods.

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[andyofcolumbusmerkur]

Looks good. I think the stock 4 runners (non-gutted) will help with the low end and getting up into boost a little faster. Always good on a street car. Here's the upper and lower intake from the SVP car. I didn't grind on these parts. But I did grind on the E6 exhaust