Ported lower Terminator intake manifold pics

[SlowSVT]

I just finished porting my lower intake and thought I would share the finished results. I'm not sure how much the engine would benefit from this but I saw a few aspects of porting this manifold that may improve the power output somewhat at higher rpm's.

My goals where clean-up the entry where it transitions to the cylinder port. add plenum area, smooth the rough cast finish of the interior and radius all the sharp corners. To that end I think I got this intake to flow about as good as one can get without resorting to welding.



Smoothing all the interior walls will reduce some of the "drag" the rough and bumpy cast surface imposes on the air. This actually removed quite a bit of materal. Adding intake plenum area to an engine is usually a good thing.

Note how the edge of the vertical wall where the ports are adjacent to one another are now a single continuous radii where the factory casting had a flat spot with sharp edge leading to the port.

The injector bosses was rounded and smoothed extensively. The web between the ports now stands up straighter opening up the pocket. Minimize compound curves and bumps at all cost everywhere.

The ports had room to grow width wise to match the intake gasket. Nice smooth transition into the cylinder heads with no bumps or sharp corners

This is a lot of work for questionable gain on an FI engine but I would not be surprised if the flow into each port improves by 30 or more cfm based on just looking at the before and after results. To what degree that translates into RWHP I don't have a clue but I like the looks of the intake better now than I did before. This intake should compliment the heads for my Boss 5.0 very nicely :rockon:

I will post some camparative photos of the fatory maniford prior to porting which a friend will be sending me.

 

[99cobra09]

Can you specify what tools did you use?

 

[JeremyAlan]

Looks great! I might tackle this one day.

 

[gabe1530]

wow very nice! how long did it take you?

 

[04svtsnke]

I don't if you e read but posi has done multiple test on his own personal car with no hp gains. I'd like to see a see some dyno numbers if you ever plan to retune

 

[SlowSVT]

Can you specify what tools did you use?

Started out with a dremel, pneumatic disc sander, all kinds of cutters, stones, abrasive disc finally graduating to Scotchbrite :nonono:

 

[SlowSVT]

wow very nice! how long did it take you?

Long time, maybe 60 hours. It's the fine shaping with the Scotchbrite that eats up the most time.

 

[05satinGT]

So what car is this going on? Or is the boss 5.0 your motor bored out? I wonder what increase in power this would see on a regular terminator motor.

 

[SlowSVT]

I don't if you e read but posi has done multiple test on his own personal car with no hp gains. I'd like to see a see some dyno numbers if you ever plan to retune

If I remember correctly Posi stated there was some gain in upper rpm's but it was nothing spectacular. There are some pretty nasty obstacles the air has to navigate before reaching the port. The entry into these inlets is quite a bit, larger, smoother and more linear then what was molded at the foundry. I was having a problem bolting up a set of carefully ported heads to something that was not as good as it could be. Unfortunately I won't be able to confirm any of this because of all the shit I've done to the engine.

 

[SlowSVT]

So what car is this going on? Or is the boss 5.0 your motor bored out? I wonder what increase in power this would see on a regular terminator motor.

It's going in an 04 with a Iron Boss 5.0 block (a 4.6 could never be bored to 5 liters). Power increase? I wonder too :lol1: I'm building a pretty high end motor that should be able to flirt with 9000 rpm's so this manifold is just one of the links in the chain.

 

[05satinGT]

Sounds like a badass build! Can't wait to see the finished product.

 

[01cobravortech]

Wow you do some great work my friend. Sure would like to know what kind of power increase came of it.

 

[SVT Pille]

I don't if you e read but posi has done multiple test on his own personal car with no hp gains. I'd like to see a see some dyno numbers if you ever plan to retune

So what car is this going on? Or is the boss 5.0 your motor bored out? I wonder what increase in power this would see on a regular terminator motor.

Steggy claims that his ported lower picks up 10 at the wheels, assuming thats with a ported blower.

OP did you do any welding on the lower? I watched a vid of Bob Stiegmier porting a lower and he welds certain parts on the exterior to add strength since he removes so much material.

 

[1320 Junkie]

I did mine a while back....I'm happy with my choice to do it, I think it definitely helps.

 

[Posi]

If I remember correctly Posi stated there was some gain in upper rpm's but it was nothing spectacular. There are some pretty nasty obstacles the air has to navigate before reaching the port. The entry into these inlets is quite a bit, larger, smoother and more linear then what was molded at the foundry. I was having a problem bolting up a set of carefully ported heads to something that was not as good as it could be. Unfortunately I won't be able to confirm any of this because of all the shit I've done to the engine.

Mine only lost 1lb of boost and I'll say that could've been because we tested in the morning and then tested again in the afternoon on the same day. So the temperature change outside could've caused that. Everything else on the dynograph was identical.

Or I say it because I'm not confident in selling ported lower intakes because of the lack of proof for gains. We sold them to cheap too because others sold them. They were priced at $400 just to have them on the Market when they take 2 hours longer to port than a blower.

Yours my friend flat out looks badass!:rockon:

 

[SlowSVT]

Mine only lost 1lb of boost and I'll say that could've been because we tested in the morning and then tested again in the afternoon on the same day. So the temperature change outside could've caused that. Everything else on the dynograph was identical.

Or I say it because I'm not confident in selling ported lower intakes because of the lack of proof for gains. We sold them to cheap too because others sold them. They were priced at $400 just to have them on the Market when they take 2 hours longer to port than a blower.

Yours my friend flat out looks badass!:rockon:

Posi, after my experience I have learned you could never offer this as a service, do it to this degree and actually make money at it (you'll probably bankrupt you're customer in the process as well :lol1.................. and I thought porting a pair of 16 valve heads was a "involved" :bored: Do you have any pics of your ported manifold you could post?

With the ported intake/heads and exhaust I would not be surprised if I lost 3 lbs but that just represents the higher volumetric efficiency of the induction system not backing as much boost up in the manifold. To do an accurate comparison test one would need to be very disciplined and is very time consuming (I should know, I've spent a good portion of my life in test labs :nonono.

As I stated I will never know to what degree this improves the output of the engine but I can say based on the work I've done this intake flows more air then before. But I would not encourage someone to do this without considering the work/benefit ratio. Porting an FI Terminator head is suppose to be worth about 25 hp and costs $1500. What's a ported intake manifold worth?

I wish I took more photo's prior porting the manifold :bash: The shots I did take where blurry except this one. You can see where I ground a single radii in the valley between both ports and removed the lip in the back of the pocket leading into the cylinder head. Look at how much of the path was blocked by the injector boss. There must have been quite a bit of turbulence leading to the heads

I like the fished results though. The heads have been reworked to the same degree as the intake and should work together quite well.

:rockon:

 

[Posi]

^My own personal lower intake which I'll add was used in my test and has about 40hours worth of work (early project that was finished later) looks exactly like yours around the outlet to the cylinder heads.:rockon: Only difference between the two is the injector bosses were cut down more than what you have.

I don't have any really good pictures either though because for some reason they're hard to get clear when you're taking them.

Race Port Lower Intake HIgh Boost Twin Screw Only

I got one in here that someone else tried to do and the first port looked like ours, second one a little less, third one less than that, fourth one scratched a little bit, and the other 4 on the other side weren't touched lol.

 

[04torchred]

Your best bet for gains has to be port matching and cutting down the injector boss area. I think the rest is nice to do, but a total time consumer for next to no real gain.

I port matched mine and shaved down the injector boss hump a bit.

 

[Posi]

^My heads are gasket matched along with the lower intake as well. Still showed no gains with the Eaton on the car. Injector bosses are cut down as far as I could without breaking through.

 

[black 10th vert]

Excellent work, OP! I did mine as well a few years back and feel confident that it definitely has to help smooth out the airflow, and add to the efficiency, even if the rwhp gains aren't huge. I agree that there is no way anyone could do this as a "for profit" service though, as I have about 40-60 hrs. of work into mine as well. I have no regrets for doing it at all. I did the whole inside, but definitely focused most of my time in the transitions into the ports, and around the injector bosses. Like Posi, I took them down as far as I could without breaking through, which not only helps with the smoothing of the transition, but also adds a little volume to the port size as well.