DIY Port and Polish for Beginners (Helpful Links)

[bob58o]

About to attempt to port and polish the head of my Hemi Predator 212cc (HF #60363). I have no experience with porting, polishing, or rotary tools (and very little with engines).

Tools Needed (what I'm using):
-Air Compressor (3 gal. Too small - need to constantly take breaks)
-Air Die Grinder (w/ 3" Extension)
-Abrasive Sanding rolls (80 grit)
-Eye, Breathing, and Hand Protection

Some topics of interest that are covered in following links:
-Die Grinder Basics
-Gasket Removal
-Rough Casting
-Sharp Edges
-Short-Side Radius
-Gasket Matching
-Port Blending
-Bowl Blending
-Valve Guides
-Valve Seats
-Unshrouding Valves
-Fuel Atomization (Roughness in Intake)
-Carbon Buildup (Smoothness in Exhaust)
-Valve Lapping
-Small Engine Carb / Intake Manifold port and polish

As a tool for me (and anybody else interested in doing this) I wanted to organize some of the useful info I found.

"How to Port and Polish Cylinder Heads"

http://www.eastwood.com/blog/eastwood-chatter/how-to-port-and-polish-cylinder-heads/

HorsePower TV VIDEO

"HORSEPOWER - HORSEPOWER'S PORT AND POLISH FOR POWER HOW-TO"
http://www.powerblocktv.com/episode...port-and-polish-for-power-how-to#.VvF_feIrLIU

"Head Porting for the Do-It-Yourselfer"

http://www.lcengineering.com/pdf/Head Porting DIY by Standard Abrasives.pdf

"Do-It-Yourself Small-Block Cylinder Head Porting"

http://www.superchevy.com/how-to/95518-small-block-cylinder-head-porting/

"Beginner's Port and Polishing"

http://www.instructables.com/id/Beginners-Port-and-Polishing/

"How to DIY gasflow, port+ polish a cylinder head" FORUM THREAD

http://audisrs.com/archive/how-to-diy-gasflow-port+-polish-a-cylinder-head__o_t__t_15304.html

Lots of Articles about compression, combustion, flow, port/polish,....

http://www.musclecardiy.com/category/cylinder-heads/

Port and Polish Predator by Hand (Wet Sandpaper)
"Polishing & Flowing Predator head Ports"
https://www.youtube.com/watch?v=0yqxjnU1O1g

ADDED: Small Engine Specific
"DIY: How to Port & Polish a Carburetor & Intake Manifold"
https://www.youtube.com/watch?v=nTKJKE1qRiA

Gasket Removal on Aluminum using plastic scraper
"Removing Old Head Gasket & Gaskets on Aluminum Auto Parts"
https://www.youtube.com/watch?v=FbDCHEzRuZo

Gasket Removal on Aluminum using 3M 120 Grit "White" Roloc Bristle Disc
"My Best Method For Cleaning Head Gasket & Other Engine Surfaces"
https://www.youtube.com/watch?v=Uy5p-cUge5s

Valve Cleaning, Shaping, Seating, Lapping / Cleaning Combustion Chamber (Steel Head)
"Cylinder Head 105 - Valve Job Basics"
https://www.youtube.com/watch?v=7GEmuQa3dPY

"Cylinder Head 204 - Porting & Polishing"
https://www.youtube.com/watch?v=iejDWSQEsqI


Armed with the tools and the instructions above, I'll try not to break it!

 

[chancer]

Even if you break it, you can always take it back LOL

 

[bob58o]

Even if you break it, you can always take it back LOL

I will surely try!!! But I got this. Getting er done today!

 

[bob58o]

Here is the Intake Port Before any work.

 

[bob58o]

Only started the Intake..

Did not use the Burr Set. Only used 80 grit tapered and cylindrical abrasive rolls in Die Grinder with 3" extension and 4" Mandrel.

Didn't mean to reshape valve guide, but it happened as I was trying to get at the casting imperfections I circled above

 

[bob58o]

Not sure if better or worse???
Going to have to take care of that, but got to be careful with the valve guide.
I noticed the mandrel tip coming out the end of the sanding roll

 

[bob58o]

And there

 

[bob58o]

Well, I'm pretty sure I can make this look good. I'll be finished fixing it up tomorrow. Hopefully I don't destroy it, if I haven't already!
I think I'll be ok, lol!??!!

 

[bob58o]

Calling the intake finished!

Finished using 80 grit. That's as fine as I wanted for better fuel atomization. It's more important in an engine with a carb (from what I read)

There was a lot more reshaping of the valve guide than I originally planned. I didn't plan on any.
BUT maybe the new shape helps some??? (That's what I'm telling myself.)
The valve guide is a whole lot thinner at the tip than I'm comfortable with. BUT if I wanted comfort, I'd live in a nudist colony

I had to go back to the 80 grit to remove those pits along the base of the valve guide.

I tried to smooth out the front edge of the valve guide too (since I was already accidentally removing material there), but since I was running out of material, I had to call it "Good Enough."

I also tried to smooth the area where the valve seat meets the intake port bowl (on short-radius side). There's a small lip. I just sanded it lightly there.

I may have touched the valve seat accidentally when tried to smooth the Short-Side Radius in a few spots (with 80 grit roll, very little pressure, short amount of time). It doesn't look too bad. I'm confident that a good lapping (either by hand or with drill and tubing attached to valve stem) should take care of it.

HERE IT IS - as of now!