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J-Man
Dodge Dakota
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6/02/2004
13:15:12
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 Subject: Modding Intake Manifold
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I was hoping that someone could help me out with this. After hearing what Larry had said about the intake manifold and how gasket matching it and cleaning up the injector bosses made a really big difference and was pretty easy, I have been thinking of trying this on my 3.9.
I kinda want some more details before I dive in, though. I can handle getting the intake manifold off, but after that, I'm not sure what to expect.
How exactly do you gasket match the intake? How long can I expect it to take. I have a Dremel, and I have already ported and polished my TB. Is this something that I can expect to be able to do this weekend?
Thanks for all your help.
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bump
Dodge Dakota
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6/02/2004
15:47:16
| RE: Modding Intake Manifold
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bump
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another mark
Dodge Dakota
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6/02/2004
18:58:18
| RE: Modding Intake Manifold
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I'm going to do the exact same thing to my intake when I go on vacation on the 20th. I'll definitely take pictures and let you know what I did. I think there is a site called fast4x4.net that has some info on this and a picture of exactly what the underside of the manifold looks like and what needs to get done. I ordered a very popular die grinder made by Makita through amazon.com for about $110 and a couple extra wheel points and I'm ready to go.
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J-man
Dodge Dakota
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6/02/2004
19:08:03
| RE: Modding Intake Manifold
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I'm not sure I want to grind down the runners too much, or anything, but I would like to port-match it. Thing is, I don't know EXACTLY what that is (sounds ridiculous, I know) or how to do it.
Is port matching and gasket matching the same thing?
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J and J Auto
GenII
 
6/02/2004
19:22:19
| RE: Modding Intake Manifold
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Message:
You will see what I am talking about once you
remove the intake and attach the old gasket to
it lining up the water marks on the intake and
attacing it with 2 bolts.
There is a big overhang into the port on top where
the injectors are, remove this not just at the
very end but back into the port.
Than just widen them out to match gasket thats not
much but the overhang is bad on these.
It will greatly increase the flow and add about
10 hp by just doing this alone
Watch your plugs after I did this on my stock
motor with all the bolt ons I had to close up the
plug gap from .060 to .055 it has that much of
an effect on the flow
We did the same thing to 3 customer trucks and all
noticed nice gains and better gas mileage very
noticeable off idle low end gains right away and
get better as it learns
Larry
J&J Auto
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Bob Lincoln
Dodge Dakota
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6/02/2004
20:14:59
| RE: Modding Intake Manifold
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Could someone post a picture (before and after) of this, so I can visualize it better?
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J and J Auto
GenII
6/03/2004
11:22:18
| RE: Modding Intake Manifold
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Message:
I was going to take some pics but I could not get
my camera to work
When the intake is off just lay a gasket over it
and you will see all the obstructions to flow in
the end of the manifold right by the machined
gasket surface
Alm from casting hanging down in the port on top
and can be widened about 1/8 on each sode to
match gasket and heads
The head port is not bad on these and is already
opened up nice unlike the intake
matching (same size) you will greatly increase
the flow capacity
Just think of it as a water pipe with the end
squesed half way shut restricting the flow same
thing here
Larry
J&J Auto
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J-man
Dodge Dakota
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6/03/2004
11:40:38
| RE: Modding Intake Manifold
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Message:
Thanks Larry, I have a better idea of it all now.
I still have a couple more questions though.
1) Does the openings in the gasket match the heads already, and I just need to open up the intake manifold ports to the same size?
2) Other than a new gasket, and a dremel, do I need anything else to do this job?
3) About how long would this take?
Thanks a lot. I am excited to try this out now!
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IntenseDak39
*GenIII*
6/03/2004
12:17:37
| RE: Modding Intake Manifold
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Message:
j-man,
it's gonna take you some time to do with a dremel. Do you know someone with a die grinder? turns hours into minutes.
here is one i just got done doing for a guy. I cut the runners down pretty far (worked really good for me so far), rounded em off, ground down any ugly castings i could find and then radiused the injector bosses. I couldnt get a very good picture of the bosses because my camera was about dead and the flash wouldnt work.
6.6 Lt. Big Block, 727 TF shift kit, 452 heads, edelbrock 750 cfm, .513/.513 284/300 crower cam, comp cams springs, comp cams pushrods, 1.5 roller rockers, dp intake, mopar ignition, mopar windage tray, dual exhaust w/ 40 series flowmasters, 4.10 gears, coilover drag suspension, approx, 3500 lbs
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J-Man
Dodge Dakota
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6/03/2004
12:27:13
| RE: Modding Intake Manifold
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Thanks Intense. Those pics are great.
Unfortunatley I only have a dremel, no access to die grinder.
So how many gaskets do I need? Three (1 for manifold bottom, two for mating surface to the heads?
I'm not sure if I have a belly pan gasket problem, but I guess it would be a good time to take a look, huh? Can I reuse it if it is OK?
This is helping me a lot, guys.
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contooki
Dodge Dakota
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6/03/2004
19:02:23
| RE: Modding Intake Manifold
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Yeah, great pics!
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Big Rick
Dodge Dakota
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6/04/2004
15:56:23
| RE: Modding Intake Manifold
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Does anyone else have a close up view of the radiused injector bosses?
BR
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IntenseDak39
*GenIII*
6/04/2004
19:04:52
| RE: Modding Intake Manifold
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I'll go to another manifold and take some before and after pix in just a bit.
..got my batteries charged now..
6.6 Lt. Big Block, 727 TF shift kit, 452 heads, edelbrock 750 cfm, .513/.513 284/300 crower cam, comp cams springs, comp cams pushrods, 1.5 roller rockers, dp intake, mopar ignition, mopar windage tray, dual exhaust w/ 40 series flowmasters, 4.10 gears, coilover drag suspension, approx, 3500 lbs
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J and J Auto
GenII
6/04/2004
19:21:01
| RE: Modding Intake Manifold
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Message:
Good picks intense
They are going to just do a port match it helps
and is easy to do, don't know if they want to
shorten the runners and remove devider,
Just port match on the 4 we done nice low end
gains and better gas mileage on stock or near
stock trucks
You can see the ports where the gasket goes between the intake and head compare those to yours
1) Does the openings in the gasket match the heads already, and I just need to open up the intake manifold ports to the same size?
Don't even think about grinding the head ports
while its on the motor, and yes they are opened
up good unlike the intake ports and are very close
to gasket size
I would also replace the pan gasket on the bottom
of the manifold you need to remove it to be sure
all the grinding crap is out of the intake don't
want thaat in your motor
Blow than wash and blow dry with gas or cleaner
to get all the grindings out
Average guy probably 4 hours to remove grind ports
clean and reinstall
Be sure you drain the radiator before you pull the
intake
intake bolts 12 to 14 foot pounds
pletium bolts 14 to 16 foot pounds, blue loctight on these also
Larry
J&J Auto
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IntenseDak39
*GenIII*
6/04/2004
21:06:14
| RE: Modding Intake Manifold
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Message:
well i didnt cut the divider out of that one. Some later years didnt have the divider in them. My stock one had one hell of a divider. I did the same treatment to mine as i did to the one above (except i did a better job to the one above) and i ground the divider flush with the new runner length.
I was VERY pleased with doing all of this. I have done it to about four manifolds (for other people) and so far two of them seem to be very happy with it (the other two havent got theirs back yet). Before i cut mine, i had a powerdyne on my truck for about two weeks. I was very pissed about the performance of it and when i took it off, that's when i decided to work on my manifold. It seriously added enough power that i didnt regret not spending the $1500 on the s/c (i got to use mine before i paid for it.. hehehe).
Some people say it will affect your low end, but those are usually people that havent even unbolted a manifold off of their truck, much less modify one. I saw no low end difference and very very good top end. Works very well with a bigger throttle body and port matched to the throttle body.
here are some pix of a manifold that was just like this one before... except this one had a leaky plenum gasket (unkown to the owner)
here is the injector boss.. hard to see because of all the carbon/oil build up.
now here are the new injector bosses... still pretty hard to see because of the glare off the shiney aluminum, but you can tell i ground down the squared edges over the injector boss. It's kinda like grinding down a valve guide to improve air flow, but this also helps the fuel atomize with the air better.
and here is the best photo of the injector boss
6.6 Lt. Big Block, 727 TF shift kit, 452 heads, edelbrock 750 cfm, .513/.513 284/300 crower cam, comp cams springs, comp cams pushrods, 1.5 roller rockers, dp intake, mopar ignition, mopar windage tray, dual exhaust w/ 40 series flowmasters, 4.10 gears, coilover drag suspension, approx, 3500 lbs
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Dan
Dodge Dakota
JOIN HERE
6/04/2004
21:49:53
| RE: Modding Intake Manifold
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Message:
photoshopped
do the work for real and stop bs'n these guys. I bet it takes ya alot longer to photoshop all of this than it would to actually do it.
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IntenseDak39
*GenIII*
6/04/2004
22:04:00
| RE: Modding Intake Manifold
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Message:
yep... people pay me to photoshop their intake manifolds.
6.6 Lt. Big Block, 727 TF shift kit, 452 heads, edelbrock 750 cfm, .513/.513 284/300 crower cam, comp cams springs, comp cams pushrods, 1.5 roller rockers, dp intake, mopar ignition, mopar windage tray, dual exhaust w/ 40 series flowmasters, 4.10 gears, coilover drag suspension, approx, 3500 lbs
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slopehead
Dodge Dakota
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6/04/2004
22:07:08
| RE: Modding Intake Manifold
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Dan is a clown, really funny, the guys that work for me all agree that the job looks good and the finish is identical to what they would expect if done in our shop.
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IntenseDak39
*GenIII*
6/04/2004
22:11:48
| RE: Modding Intake Manifold
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Message:
thanx slopehead... but you shoulda seen the one i first did. It sucked having to remove the divider.. but i also did most of the work with a dremel. I bought new tools and new attachments and it makes the job a WHOLE lot easier and cleaner.
6.6 Lt. Big Block, 727 TF shift kit, 452 heads, edelbrock 750 cfm, .513/.513 284/300 crower cam, comp cams springs, comp cams pushrods, 1.5 roller rockers, dp intake, mopar ignition, mopar windage tray, dual exhaust w/ 40 series flowmasters, 4.10 gears, coilover drag suspension, approx, 3500 lbs
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quickbrick
Dodge Dakota
JOIN HERE
6/05/2004
00:15:15
| RE: Modding Intake Manifold
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you must work in a sh!tty shop slopehead
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J and J Auto
GenII
6/05/2004
08:22:16
| RE: Modding Intake Manifold
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92 to 95 had the divider and the egr tube that
exsited right under the throttle body
in 96 they removed the egr tube from the intakes
around 97 98 they also stoped using the divider
Just doing the port match helps a lot with low end
if you want more power up higher shorten the
runners but for most the low end gain is more
usfull, helps at crusing speeds
It all depends on how you drive your truck
Larry
J&J Auto
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