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Old 06-05-2006, 01:33 AM   #1
02WHITEDUB
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Member#: 96793
Join Date: Sep 2005
Chapter/Region: W. Canada
Location: Edmonton
Vehicle:
02 ProTuned TD04
Now with more clunks!

Smile Port & Polish for the ProTune!

I've never P & P'd anything in my life, but after reading 'P & P Madness' and a few other things, I think I'm ready to try a couple of things...

First, I'll do my IC inlet elbows. Cheap part, probably easiest to do. Will be good to 'learn' on. Probably no gains but everything helps!
If that goes well, I'll do my throttlebody inlet. It looks easy as well, and is reputed to be quite an effective mod.

I'll drive that around for a week or two, and if the spirit moves me, I'll do my exhaust manifolds and crosspipe. The consensus is that doing these have a noticeable effect on spool and responsiveness. While I have them off, I may as well give the manifolds a DIY thermal coating. The crosspipe being stainless instead of cast, I'll remove the heat shield, coat it, and replace the heat shield.

So, I'm looking for a cheap die-grinder (I have access to a compressor) and some cheap bits/wheels/stones. I saw a Coleman one at Wal-Mart for about $30, Cdn Tire about the same for a cheap JobMate.

I'm gonna look at Princess Auto, but where else could I get the consumables for a reasonable price? House of Tools?

If anyone's interested, my shop has a huge compressor with two hoses. So...I could host a little thing if anyone wanted. Experienced Port & Polishers would be very welcome!

So, yeah, where can I get cheap/good abrasives?
Does anyone have spare OEM exhaust manifolds + crosspipe for an 02 sitting around? It would be better to do it on 'spare' parts, then I just have to swap = less down time!

Here's the P&P thread that got me going!
http://forums.nasioc.com/forums/show...ht=port+polish
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Old 06-06-2006, 08:56 PM   #2
02WHITEDUB
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Member#: 96793
Join Date: Sep 2005
Chapter/Region: W. Canada
Location: Edmonton
Vehicle:
02 ProTuned TD04
Now with more clunks!

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Wow, I'm surprised nobody seems interested in an effective, 'free' mod (except for the abrasives.)

I'll post some pics and impressions here anyways - when I'm done.

I fear that doing this will be VERY time-consuming, with noticeable but not amazing results. I figure the hours spent versus the improvement will be a sad, sad ratio. I'll still do it though...and let the dyno tell the story!
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Old 06-06-2006, 11:00 PM   #3
Jitenshakun
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Member#: 61586
Join Date: May 2004
Chapter/Region: W. Canada
Location: Alberta
Vehicle:
2005 STi
WI and all the goodies

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If you're going to P&P your OEM manifold you may want to buy an Injen crossover pipe to go with them. Our stock crossover pipes are pretty thin so you can't really do anything with them.

FWIW I have a P,P&TC'd OEM exhaust manifold. There's a thread in the 2.5L forum that'll show you your time on the header is worth it.

-J
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Old 06-06-2006, 11:07 PM   #4
02WHITEDUB
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Vehicle:
02 ProTuned TD04
Now with more clunks!

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I've seen a couple crosspipes that people here have coated, heat-wrapped, and replaced the heat shield. That would increase the effectiveness of the stock part enough for me, I think.
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Old 06-06-2006, 11:37 PM   #5
Jitenshakun
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WI and all the goodies

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When you see how restrictive the manifolds are you'll wanna P&P 'em. They're really short so if you have a decent compressor and a couple bits from crappy tire you'll be pretty happy.

On a 2.5L (untuned) you can get about ~10 whp & 15 wtq (dyno "proven").

-J
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Old 06-07-2006, 12:51 PM   #6
02WHITEDUB
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Join Date: Sep 2005
Chapter/Region: W. Canada
Location: Edmonton
Vehicle:
02 ProTuned TD04
Now with more clunks!

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Yeah, I removed one for my UP and EGT install. They're pretty nasty inside!
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Old 06-08-2006, 02:38 PM   #7
John__Gotti
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Location: Red Deer, Alberta
Vehicle:
The Oil patch, as
fun as it sounds

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Sounds like a good idea. If I had the time to do this I would also. It is going to be tuff to just get my vf34 and supporting equiment on in time.
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Old 06-25-2006, 10:17 PM   #8
02WHITEDUB
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Join Date: Sep 2005
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Location: Edmonton
Vehicle:
02 ProTuned TD04
Now with more clunks!

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So, today I tackled Stage One of my little P&P project!
A friend let me use his air tools at his shop, and in 3 hours I was done!

The IC inlet elbows were first. I started by using a carbide burr for about 20 seconds but didn't like how rough it was grinding. I switched to a flapper wheel (about 180 grit) and did the rest of both elbows with only the flapper.
I only went in about 1.75" but I went a little deeper on the casting marks.
It was EASY and only took about an hour of grinding/sanding to get results like in the borrowed picture below.



Next, the throttlebody. Easy to remove with the IC already off, it took an extra 10 minutes to remove for a n00b.
I did the TB the same: Flapper wheel only, basically going around and around the inside while rotating the piece and standing in different spots to eliminate any deep/shallow grinds. I went about 1" deep with a smooth taper.

While I was in there I noticed how much the bottoms of the screws in the butterfly protrude (4 threads or so) so I carefully hand-filed them down to about 1 thread sticking out.

My results were similar to the borrowed pics below, except with a less polished finish.


^^Nasty edge there^^



^^That's better!^^

My impression so far is that my car felt really strong, with smooth throttle response, for such a hot day. That's probably just wishful thinking, but it couldn't have hurt.

Next up: Headers
Anyone know of a CHEAP way to do a thermal coating on these babies? Anything at PartSource or JB's etc?

Last edited by 02WHITEDUB; 07-09-2006 at 03:55 AM.
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Old 07-06-2006, 07:29 PM   #9
06rexwagon
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Chapter/Region: SWIC
Location: Albuquerque, NM
Vehicle:
2006 WRX Limited Wag
9.8@150

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good work. I'd like to do a P&P on my TD04 and tune it with my street tuner. Anyone have a guide on how to P&P a turbo?
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Old 07-06-2006, 07:55 PM   #10
Flexx999
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A cheap away for thermal coating your headers would have to be the heat wrap. I did my down pipe and it isnt expensive at all.
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Old 07-06-2006, 08:49 PM   #11
Rat Fink
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Rally Blue

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They say heat wrap traps in moisture and promotes corrosion though.....I've heard stories of headers not even lasting a year after they've been wrapped.

Theres a company called Jet Hot....they're a little pricey because you'd have to send your parts to them to be coated......but from what I hear their ceramic coatings come back super shiny, and don't discolor, bubble, or peel.

There's a place in Calgary called top gun coatings.

A company in Red Deer called Metalstrip and Coatings Inc.

and a company in Edmonton called Perfection.

Not sure how the local guys are....but I hear they're cheaper.
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Old 07-06-2006, 09:31 PM   #12
mac_82
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I had the header for my civic done at top gun, they did a really good job on it.
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Old 07-12-2006, 03:55 AM   #13
02WHITEDUB
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Join Date: Sep 2005
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Location: Edmonton
Vehicle:
02 ProTuned TD04
Now with more clunks!

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I called Perfection the other day and was quoted about $220 for a ceramic coating of headers and crosspipe. This was over the phone though...I'm sure I could get a better price going down there as they probably do big V8 headers. I also had Marty at ProMax Performance (usually muscle car/truck stuff) quote me about $140 for the same service. Does this sound about right? I'd FAR prefer ceramic to heat wrap.

I was also lucky enough to 'borrow' a set of headers to do in my spare time! I'll take some pics of the progress!

I need to get these P&P'd headers installed - along with a turbo inlet and sparkplugs before the ProTune! I'm gonna be busy...
Maybe I'll finally hook up that IC sprayer...*sigh*

And re-wire my power block...
And fix my clock...
And replace that headlight bulb that's a bitch to get at...
.......
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Old 07-12-2006, 10:37 PM   #14
Rat Fink
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Rally Blue

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I'm totally new to 4 cylinders. sounds like that quote isn't too far out to lunch. I've heard of V8 headers costing 250ish.
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Old 07-21-2006, 07:53 PM   #15
02WHITEDUB
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Member#: 96793
Join Date: Sep 2005
Chapter/Region: W. Canada
Location: Edmonton
Vehicle:
02 ProTuned TD04
Now with more clunks!

Default

Whew! All done!

I worked on my car from 7:00pm until 4:30am and got everything installed, and leak-free! That left me 4 hours until my ProTune slot - plenty of time to spare!

Can't really say what gains the headers might have given because I also swapped plugs, fuel/air/oil filters at the same time, but the car felt great on the drive out to the dyno.

I ended up putting down 235wtq and 229whp on a conservative, safe tune on 91 kerosene. We need to get some basic stage 2 WRX results in so I can see if all of this P&P action made a measurable difference - though my butt dyno is a finely-calibrated instrument and it says 'Yes.'

Sorry, no pics of the header portions, but I will say that I learned that having a floor creeper is invaluable. I did my UP/DP without one and my back was raw for days. I also found a die grinder with a skinny 6" shaft so I got all the way into them except for a 2" portion on the passenger-side header.

Anyways, don't just sit there, DO IT! It's easy, and I'll be happy to sell/lend my skinny die-grinder to any aspiring P&P artistes. It was REALLY hard to find. House of Tools didn't even think they existed...
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