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Old 09-25-2008, 08:37 PM   #1
Koji
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Default PSA: Port and Polish your Ebay IC Elbows. Now!

I bought a CSS performance TMIC intercooler off eBay a while back. While I was putting the thing together I noticed that the inlets on the intercooler and the inlets/outlets on the elbows werenít nearly gasket matched and that there were a lot of rough spots on each.

I needed a break from working this past weekend so I took off the intercooler and ported/polished the intercooler (both the inlets and the outlet) and all of the elbows. I didnít think this would do much, but it made acceleration a lot smoother.

Boost also comes on earlier (which is great as I have a VF39 which doesnít exactly spool like a 16G). In fact, my boost comes on so much earlier that my previously safe and completely knock free UTEC map is actually pinging between 2900 and 3500 RMPís if Iím at part throttle then nail it.

I laid a gasket on the elbows and then used a felt pen to mark off the gasket outline. Everything marked in black was removed. You can also see how rough the insides of the elbows are from casting.







Hereís what the inlet from the turbo looks like. Itís got tons of ridges and generally looks like hell.



None of my after pictures turned out except for this one, but itís noticeably smoother:



If you have one of these ICís, or any IC with cast aluminum elbows, Port and Polish them.

Happy Modding!
Koji
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Old 09-25-2008, 10:46 PM   #2
Koji
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I hit 23PSI today at 3600RPM's (target is 19) just driving on the freeway. It's never done that before so it's pretty safe to say the change is significant.
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Old 09-25-2008, 11:12 PM   #3
2gnt2wrx
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Quote:
Originally Posted by Koji View Post
I hit 23PSI today at 3600RPM's (target is 19) just driving on the freeway. It's never done that before so it's pretty safe to say the change is significant.
Thats common when driving on the highway. But not necessarily a good thing.
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Old 09-25-2008, 11:21 PM   #4
Koji
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The issue is that before the porting/polishing I'd always peg right to target boost and hold steady.

Last edited by Koji; 09-30-2008 at 12:31 PM.
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Old 09-26-2008, 12:09 AM   #5
WRXislander
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There's a massive thread on this. Stock intercooler elbows need pnp'ing just as badly and when you do it you get the same good results.

PnP Madness!:
http://forums.nasioc.com/forums/showthread.php?t=729711
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Old 09-26-2008, 06:56 AM   #6
Spenk
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Quote:
Originally Posted by Koji View Post
I hit 23PSI today at 3600RPM's (target is 19) just driving on the freeway. It's never done that before so it's pretty safe to say the change is significant.
Just as significant and unsafe as running lean. You should definately get a retune.
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Old 09-26-2008, 08:00 AM   #7
axelthrasher
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There are numerous things that you can port and knife edge on the intake side of things to make everything flow smoother. I usually start with the intercooler and the elbows, then knife edge the throttle body, gasket match the intake manifold, delete the TGVs and gasket match those, and of course finish out with doing the intake side of the turbo along with the turbine inlet. That is needless to say if you've got headers - otherwise you might as well port the stock exhaust manifold too.

That much definately helps with spool up of the turbo.

A little teaser -
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Old 09-26-2008, 02:27 PM   #8
busymind
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May sound dumb but what did you do to keep the shavings from getting all in the TMIC? Just vacuum them out???
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Old 09-26-2008, 02:37 PM   #9
Koji
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I used shop rags stuffed into all the holes, then blew air through them with a compressor along with some brake cleaner. This method worked well.
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Old 09-26-2008, 02:38 PM   #10
Koji
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Quote:
Originally Posted by Spenk View Post
Just as significant and unsafe as running lean. You should definately get a retune.
That is the plan. I'll probably start tweaking the boost map this weekend. I've got a methanol kit installed now as well so a retune was on the horizon in any event.
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Old 09-26-2008, 04:06 PM   #11
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Quote:
Originally Posted by axelthrasher View Post
A little teaser -
****ing sick job man...
... wanna port a bunch of things on my car lol ???
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Old 09-26-2008, 04:34 PM   #12
mlovro32
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Koji,

So was this mod number 33 or did I miss reading over this one???
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Old 09-26-2008, 04:40 PM   #13
Koji
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This was just something I did . The birthday weekend is over, but I'm not done modding by any means.
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Old 09-26-2008, 07:34 PM   #14
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I noticed the same thing with my ebay elbows, but i didn't have a before and after like you. Just saw they were narsty and p&p'd them before install.
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Old 09-26-2008, 11:34 PM   #15
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Quote:
Originally Posted by Koji View Post
I used shop rags stuffed into all the holes, then blew air through them with a compressor along with some brake cleaner. This method worked well.
really oily shop rags work best, in fact dump some oil on them after stuffing them in the hole. (the metal flakes stick to the oil.)
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Old 09-26-2008, 11:46 PM   #16
PolarisSnT
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Ive got to pull of my PWR TMIC and try this. Here is my throttle body that I did about 2 years ago.

Stock:


After:


Probably could be better but it is a smooth transition from the coupler when it is properly clamped down.
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Old 09-26-2008, 11:50 PM   #17
Koji
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That looks pretty good. Doing the TB and the TGV's is next on my list of stuff to do (along with a grimmspeed phenolic spacer when I put things back in).
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Old 09-26-2008, 11:54 PM   #18
Koji
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Oh, and the turbo too. . I'll be stuck with the VF39 for a while so I need to make the most of it...
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