DIY: Gasket Matching (Head or Intake Manifold)

[Kaan]

I got bored today I had the day off and some time to kill. Im doing a gasket match on the head that is going to accept the manifold I recently ported. The manifold went from a stock 3290cc to 4485cc! Its also a super long runner set up for some TQ.

I started with these tools: carbide bit, sanding drum, flap wheel, and a sharpie


You start with marking the head (or manifold if you are doing one of those) with a sharpie. I put my reusable manifold gasket on the head, clamped it in place (some people tape it), made some realignment marks (so I can check things multiple times), and then marked the difference between the head and the gasket. I also ran a plum bob and laid down a flat line to measure the ports from you can do this if you want its a little over board.


I then removed the gasket and started with the carbide bit. This is what it looks like when you first start. Take your time dont cut to deep into the head or take too much out at once. Follow the flow of the port and try to keep it uniform for best results.


The next step is to use the sanding drum. I used an 80 grit drum. Again, follow the port, donÔÇÖt take too much off and smooth out any issues you had with the carbide bit.


I also recheck after this step. To see what needs to get worked down and how close I really am the sharpie doesnt always work out to be 100% accurate.


The next step was to use the flap wheel 200ish grit. Work your way in a little and make sure you keep things smooth.


We started with: 47.89mm (.05mm variance between all the ports on the plumed line)


I ended up with: 50.94mm (my variance was still .05mm)


Hopefully this matches up well with the manifold I ported.

[Kaan]

i have completed the exhaust side of the head. I will probably post some pictures soon. i also "built" a head holder out of a box... super important to keep things level and easy to flip/rotate the head.

two things to note:
1. when using sanding drums with the dremel, keep your RPMs down around 6-8k or you will burn through sanding drums
2. the dremel rotates clockwise and i found it easier to control when i moved the dremel COUNTER clockwise (or oppostite the spin)

[DierwulfBL]

Excellent write up Kaan! One question, when you're done how did you clean up all the metal filings? You just gonna get the head hot tanked or do you have any special tips for that as well. I've been lookin to pickup a z6 head to practice on and I was thinking just hot tanking after wards on all parts but if theres a way to save money that's even better