Hey guys, not sure if many of you have done this, but last week I was installing my NewSouth Performance PowerGasket Plus, and while I had the intake manifold off, decided to port and polish it, and match it to the powergasket. The results were very impressive. It is showing more peak torque, as well as a flatter torque curve... As well, the peak hp is up, and the hp curve is much broader, not dropping off so fast after 5k rpm as is normal with the K03. On the intake mani ports I had to grind down quite a bit, ranging from about 1/32" to as much as 1/8" at some points. Average was probably about 1/16" in most places. I can post more info and some (crappy) pics if anyone is interested.

 

Great job and for sure post up some pics. In fact put together a DIY with pics and description and submit for inclusion into the DIY section.

Thanks

 

Did you install a large-port gasket? Porting the manifold runners, then having them flow directly into a small-port head is going to create a disruption, killing laminar flow, which will hurt power, not improve it.

Or did you use a transition gasket (large-port to small-port)?

 

i will put together a DIY soon.... but it will have to wait until i have a little extra time after the riders win the grey cup this weekend!

No, i used the proper small port gasket, but if you disassemble yours, i am sure you will find that, in fact, the manifold runners are (somewhat) significantly smaller than the actual intake ports on the head itself. i did not touch the head (though i would have if the gasket itself had been bigger than the head ports - in the interest of gasket matching)
so, right now, the intake runners perfectly match the diameter of the heads intake ports, and the gasket itself. also, i did not put a "mirror" finish on the polish (in case of puddling in the runner), but i did smooth it out quite a lot, starting with a sanding head on my die grinder, and finishing with a flapper wheel, then cleaning it with wd40 and a scotch brite pad, then a soapy water scrub, a few clean water rinses, compressed air to help dry, followed by a rinse with intake cleaner, then compressed air to finish. i believe that this will help to increase the velocity of the air as it enters the head, and promote laminar airflow.

here are a few of the (crappy) pics i took

 

Ahhhh, okay! I just wanted to make sure that you weren't leaving a lip in there - it would hurt power! I wouldn't know about gasket-matching a small-port manifold as I have a large-port head from an AEB engine. Good job, though - one of the very few things that you can do to a car to pick up 'free' power. There are a few EU manifolds that flow better as well and can be had for cheap, but it's probably not worth it unless you're getting rid of your current restriction - your tiny turbo Time to slap a 2871R on there!

Also, I wouldn't touch the head unless you have experience with it, or a flow bench. Porting heads is somewhat of an art, and I've seen more than one person lose power with a DIY job. That, and it's pretty risky to do with the head assembled - no way would I try that!

 

yeah, i see that in your sig now... did you see a big difference after installing the AEB head? always been curious.
as for working on the head while attached, the tricks i have read about are to stuff wd40 soaked shop towels down into the port, then spray in shaving foam... this will suspend and particles, then vacuum the whole bloody mess out. i actually had my head prepped for the work, but when i fit up the powergasket, i found that it was a perfect match to the head.
unfortunately, while i had it all apart, i forgot to gasket match and polish the throttle body.... next time, i guess!
and you are right about the turbo! although i think i will likely end up goind with a K04 down the road, nothing bigger. i don't want to go to far with mods, as down the road i want either something with a 2.7T or a 4.2

 

You're really only going to benefit from an AEB once you go big turbo (GT28+) - you can spend your money in a lot better places until then.

Yeah, you can stuff the head to try to catch all the shavings when porting, but I'd just rather do it properly and pull the head. I'd just wait until a t-belt is almost due anyway, then it's not much extra work to pull the head. Good time to do rods and rings, too - then your motor is good for 5-600HP.

K04 is okay - definitely an improvement on the K03 - but I wouldn't bother if you know that you're going to a 2.7TT or 4.2 anyway. Like I always say, a chipped, turbo-back 1.8T with a properly setup suspension and tires is one helluva daily driver! That will probably hold you over until you get some more cubic inches