I have been meaning to do this now for several months, but I finally got around to giving it a shot. I modeled it after DB's modded intake, but the website that use to have the instructions took it down! So, I just did it by memory. Let me know what ya'll think, and if there is more I should do. I ported and polished both ends of the intake.

I think I should send ours to you!!!! Looks good!

There is always a price...

I got alot closer to the middle bolt hole on mine. Did you do the ports so that they match the head better?

This was my lame attempt at it...

CB- You took a lot more out than I did- What did you do to the gasket to fit those openings? Do you think I should I take more out, or would you leave it lone?

I just don't have the skill or patience required. I tried forever to get it all purty like yours, but never could get it to look like that. I used the grinding bits that db8 suggested. Then a sanding wheel. Then took a buffing compound and polishing wheel to it. It is smooth to the touch but not quite so photogenic... Yall think the way mine is would hurt performance?

SP, that is a kohler intake. I wouldn't know what to tell you to do with yours. I wasn't thoroughly impressed with the job that I did. I didn't use a gasket for it either, just a gasket maker/sealant.

Well this was this second go at it. The first one I took too much out of the inside pipe, and I went right through the intake at the bend! I was a little more cautious this time!

I could probably take more out down by the middle bolt hole like Owen said, but sanding the damn thing takes some time! I was doing it by hand!

All of the sanding was done by hand! Everything else was done with a dremel. I started with a 220, and then I went to a 400 and then finished with a 1500. I can't remember which bit I used in the dremel, I want to say ti was a 119? Cylinder shape used on soft metals. I bought two, one smaller cylinder, and another that was a little larger. I used the larger one mostly. It was too easy to dig grooves with the smaller one.

Final Result. I cleaned things up today, and took more out at the bend on the inside and one more good pass with the dremel around the perimeter. Sanded, and now it is ready to go on! Thx DB for the directions a while back.

i may still do that, but I thought I would see how this does before I go all the way. If I need to do more, I will. Thank you for the advice, if I had read it earlier you may have changed my mind! Here are the install pictures.

When I cranked it up, it was obvious I was going to have to adjust all of the settings. The motor was idling at 1850 when I had it set to around 1150-1200 before the intake! I readjusted the air mixture screw on the Mikuni and reset the idle. It is now idling at 1250 at about 1 1/2 turns out. To early to tell what it will do on the water, but it sounds good on the trailer.

Looks good. I never went any finer grit than 80 though, you want some tension on the walls so the atomized fuel doesn't stick to it. I used the dremel flap wheel as far as you can get in and then modified a flex hone with a flexible shaft to run through the whole thing. When I was doing them as kits, that was the secret sauce. I did a bunch of kits, upgraded my shotgun, then retired and put up that post (on the site that can't be named) to show others how to do it. I still have a bunch of in-progress pics on photobucket:

http://s168.photobucket.com/albums/u182 ... b/Intakes/

So you are saying the 1500 I used to finish the sanding was a little fine? How would you know if the fuel was sticking to the intake? If this is a problem, I can break the dremel back out, and then use the 80 to sand it down. Thx for the input.

Well....the exhaust side is good then!

Looks like it will flow much better. Is this a stock intake?

Good Stuff!

Looks really good SP! I did a few intakes with the threaded bolt hole in the lower middle like that and if its not being used (like on a vertical intake) than you can get as close as you want to it. I also went a little farther on mine using a little whale fin technology. lol


You got mad skills Gary or should I say Master!

Heres a couple pics of how I cleaned mine up to show how close I got to the bolt hole.





Intake adaptor.



And these are a couple shots of the one I put the whale fin tech on. lol According to studys its suppose to cut down on wind drag 20% or more.





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thats awesome work guys.

Nicely done bayouboy! What bit did you use on your dremel and what is up with the "teeth" marks in the last picture? Thx for sharing!