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

[andyofcolumbusmerkur]

This lower intake doesn't have the extra weld like yours, that is pretty cool. The bump on the inside is still there even after the porting. No bump on the first and fourth runner, and just a small bump on two and three. The upper is ported pretty well but I think I could port it a little more. It is like the person doing the porting stopped because they didn't want anything too thin.