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Since I'm on vacation and the headgaskets are starting to go.. I figured I'd just dive in. I'm on a budget so for now I need to keep it cheap.. That means stock cam for now. I will be port-matching everything (including heads) and may even do some exhaust bowl porting when the heads are off. I will be dis-assembling the heads and replacing valve seals too. No need for a valve job, this car only has 54k miles.

Started with the throttle body. It has been half-shafted, and the transitions in front and rear of the throttle plate have been blended and polished. I also made the throttle plate a little thinner.. Pics:
 

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Discussion Starter #2
2 of many..
 

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Discussion Starter #3
throttle body gasket match ported..
 

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Discussion Starter #4
front of throttle body
 

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Discussion Starter #5
upper intake throttle body opening ported, throttle body mating surface machined..
 

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Discussion Starter #6
upper plenum gasket matched..
 

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Discussion Starter #7
upper to lower intake gasket matching half way complete..
 

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Discussion Starter #8
unported runners that have yet to be matched..
 

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Discussion Starter #9
ported and matched runners.. Big Difference!
 

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:coolgleam: ::Takes out notepad:: I'm watching this very closely
 

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Originally posted by MaltaTaurus69@Sep 9 2004, 08:37 PM
:coolgleam: ::Takes out notepad:: I'm watching this very closely
I didn't give you those extra parts for nothing, Lucas. B)
 

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Originally posted by Racer X+Sep 10 2004, 02:41 AM--><table border='0' align='center' width='95%' cellpadding='3' cellspacing='1'><tr><td>QUOTE (Racer X @ Sep 10 2004, 02:41 AM)</td></tr><tr><td id='QUOTE'> <!--QuoteBegin-MaltaTaurus69@Sep 9 2004, 08:37 PM
:coolgleam:  ::Takes out notepad::  I'm watching this very closely
I didn't give you those extra parts for nothing, Lucas. B) [/b][/quote]
:lol2: Time to start having some fun, I need a dremel.
 

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I was just going to ask what tool you were using. I assumed that you were using a Dremel...what bits/wheels are you using?

JR
 

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Discussion Starter #16
It really cleaned up that well!

I am using a dremel.. I've tried a few different bits, but something I stumbled upon actually works very well.. A drywall cutout bit. It looks like an agressive drill bit, and with a little cutting oil it works very well.

After I do the ruff cutting, I blend with coarse sanding drums, then switch to medium and leave it at that.

I am doing this all with a dremel and a flex shaft attachment. Its not difficult, just very time consuming.

I also have an extra set of police package heads that I was tempted to throw on because of the larger exhaust valve, but the open combustion chamber would lose quite a bit of compression, unless I milled the block and heads..

Jeramie
 

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Discussion Starter #17
More pics! Engine stripped down..
 

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Discussion Starter #18
the heads I pulled off the car had a pretty bad sealing surface (probably why the gasket blew.) It was just from a poor casting process..

So since I didn't have time to mill them, I ended up using my '95 police package heads (they had already been milled .010)

Top pic is the police package heads, and the bottom is the regular 3.8L heads.

The popo heads did lower my compression a little (the police engine uses different pistons), but not much. The end result from the port matching gained me a little even considering the lost compression. The car isn't as snappy off idle, but it revs happier now.
 

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Discussion Starter #19
Here's the new felpro gasket in place, all dressed and ready for the head.
 

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Discussion Starter #20
police heads installed, torqued, and ready for everything else!
 

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