Going to start my port and polish of my intake tonight - 2003-04 Mach 1 Registry Owners Club

Comp Orange 04 · 12-16-2004, 03:06 PM

Well the process has started. Let me tell you getting those dang port plugs out was a pain in the ***! Tried many a technique and when all the smoke cleared I wound up drilling a pilot hole, making it bigger with screwdrivers prying up at the same time, then forcing it out with vise grips. Here is a picture (I believe) of the part number for the freeze plugs:

Here is what a plug looks like after it is forcefully removed:

All the plugs out:

And started the process. I need to go out and get a little rougher grit set of stones for my dremel so I will post more later. This is going to take a while....

Aerowrench · 01-03-2007, 07:39 PM

Quote:

Originally Posted by Comp Orange 04

Well the process has started. Let me tell you getting those dang port plugs out was a pain in the ***! Tried many a technique and when all the smoke cleared I wound up drilling a pilot hole, making it bigger with screwdrivers prying up at the same time, then forcing it out with vise grips. Here is a picture (I believe) of the part number for the freeze plugs:

And started the process. I need to go out and get a little rougher grit set of stones for my dremel so I will post more later. This is going to take a while....

The numbers you see are the port plug part # Prefix and Suffix. You'll need to get the basic part # (middle #) to complete it. Your local Ford guy should have it, might be the same "basic #" as the manifold.

I'd try aluminum-oxide sanding drums/ cones or a rotary file/ double-cut bit to rough it out. Just a thought.

ster!nn · 03-03-2007, 10:47 PM

Hey, I've been reading this thread over and over for a few months now and I finally got the nerve to tackle it.
For the past 1 1/2 hours I've been disassemblying my intake and finally got the lower intake out. What a pain ERG, bah.

Anyway, I see that people have been epoxying the lower back together. What's everyone's opinion on that? Weld or epoxy? I'll start the grinding tomorrow and the rest of the week.

Nazman · 03-04-2007, 12:39 AM

Quote:

Originally Posted by ster!nn

Hey, I've been reading this thread over and over for a few months now and I finally got the nerve to tackle it.
For the past 1 1/2 hours I've been disassemblying my intake and finally got the lower intake out. What a pain ERG, bah.

Anyway, I see that people have been epoxying the lower back together. What's everyone's opinion on that? Weld or epoxy? I'll start the grinding tomorrow and the rest of the week.

...

Angus66 · 03-04-2007, 07:10 AM

Looks great Naz! :THUMBSUP:

Nazman · 03-04-2007, 01:21 PM

Quote:

Originally Posted by Angus66

Looks great Naz! :THUMBSUP:

Thanks brother!

ster!nn · 03-04-2007, 04:06 PM

Why do you do epoxy work on the bottom side where the plugs are? For better flow eliminating sharp edges?

12-16-2004, 03:06 PM	#1
Comp Orange 04 Registered User Join Date: Nov 2003 Location: Normal, Illinois Posts: 461	Well the process has started. Let me tell you getting those dang port plugs out was a pain in the ***! Tried many a technique and when all the smoke cleared I wound up drilling a pilot hole, making it bigger with screwdrivers prying up at the same time, then forcing it out with vise grips. Here is a picture (I believe) of the part number for the freeze plugs: Here is what a plug looks like after it is forcefully removed: All the plugs out: And started the process. I need to go out and get a little rougher grit set of stones for my dremel so I will post more later. This is going to take a while.... __________________ 2004 Competition Orange Build Date 11/04/03 277.1 RWHP 301.2 RWTQ 1/28/04 SAE Stock 294.2 RWHP 314.0 RWTQ 1/25/05 SAE. 12.61@108MPH 04/16/06 Magnaflow Magnapaks,MRT Catted H pipe SCT Xcalibrator tune,Ported/Polished lower intake with PHP spacer,S&B 8" Powerstack filter on Lowes CAI, MGW Shifter, Strange 31 spline axles, FRPP 31 spline diff with carbon fiber clutches, FRPP 4.10 gears,17x9 and 17x10.5 Black FR500 rims, BFG drag radials

03-03-2007, 10:47 PM	#3
ster!nn Registered User Join Date: Mar 2007 Location: Grand Junction, CO Posts: 287	Re: Going to start my port and polish of my intake tonight Hey, I've been reading this thread over and over for a few months now and I finally got the nerve to tackle it. For the past 1 1/2 hours I've been disassemblying my intake and finally got the lower intake out. What a pain ERG, bah. Anyway, I see that people have been epoxying the lower back together. What's everyone's opinion on that? Weld or epoxy? I'll start the grinding tomorrow and the rest of the week. Last edited by ster!nn; 03-03-2007 at 11:02 PM.

03-04-2007, 07:10 AM	#5
Angus66 1/4 Mile Drags Moderator Join Date: Aug 2003 Location: Guntersville, AL Posts: 2,630	Re: Going to start my port and polish of my intake tonight Looks great Naz! :THUMBSUP:

03-04-2007, 04:06 PM	#7
ster!nn Registered User Join Date: Mar 2007 Location: Grand Junction, CO Posts: 287	Re: Going to start my port and polish of my intake tonight Why do you do epoxy work on the bottom side where the plugs are? For better flow eliminating sharp edges?

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