Has anyone done this or seen it done? I measured my heads and measured my a spare intake. The intake runner is thinner than the intake port on the head, by a considerable amount. I was thinking that you could enlarge the runner on the intake and maybe just sand the intake at the throttle body opening alittle. It probably wouldn't do any good a a stock or mildly modified 5.3 but, on a larger motor or a cammed 6.0. It might help out the upper rpm range alittle.
I will start to fart around with my spare intake and see if you could take the intake port out far enough. I know the intake port and the TB is pretty thin so there might be a limit right there.
I do not have the money for a intake swap right now, I have to buy a new locker, cal-tracs, driveshaft loop, new tires, and finish my direct port fuel system. Plus, I just spent money on getting some dents fixed and getting the thing buffed.
I believe that my intake is really holding the motor back on power.
Any ideas or suggestions?

 

Ttt...

 

I haven't. It seems like at least a few potential ponies could be had by port matching. Like you already mentioned though, ya be careful to not go too big as cracking could happen with these composite manifolds.
I don't know if they have thicker castings, but on the LSX manifold, there are guideline grooves on the intake ports showing you the maximum limit one could take out. You might look at a picture of the LSX intake ports to see how far out they are able to take theirs out to. ...the lsx may have thicker runners though also allowing more to be hogged out...

 

SF,

You are creating alot of power. You should consider the FAST manifold if your budget will allow it.

 

No porting is suggested or recommended on the stock manifolds.
The LSX intake does allow for port matching and has notches in the runners to show you how much can be "shaved". Use caution as those intakes are mucho expensive!

 

What about extrude honing? It's a nifty process where abrasive media is pumped into any tube and pumped back and forth at high pressures to lightly deburr and polish any material. The grit of the goop that is used in the process can vary to remove material as well.
http://www.extrudehone.com/powerflow.html

 

The process looks promising. I am familiar with it from its use in the motorcycle industry.
The only thing is the composition of the intake material. Not sure if the honing process would help or hurt.

 

What would you use on the nylon composite material? You can't just use the Standard Abrassive porting kit. Conventional sand rolls, carbide bits etc might not work on the stock intake. If you've ever sanded or grinded on plastic you know what kind of finish it can leave. Something to think about.

 

I've already tried to port a stock LS1 intake and destroyed it.....you can't remove very much material before you blow through the walls....or in my case make them so thin that you can flex the runner with the your fingers, you can't even get the port opening to the same size as the stock runner dimensions

 

Well....there ya go! Sounds like a PITA to me. Sorry about your intake Yelo, that sucks. Thanks for being a pioneer and taking one for the team!