Poolshark1321
07-14-2010, 10:35 PM
I have ported a handful of LS1 and LS2 TBs for friends and figured someone can use a good guide to DIY. Overall I found it very easy and it took me 3 hours total... from popping the hood to cleaning up and slamming it shut.
Tools I used... ( you can substitute different size sand rolls or even use flapper wheels if you like. I just used what I had at the time and it worked fine. You might consider using some 36 grit sand paper for the rough work and then come back with some 60, 120, 200 and so on and so on depending on how smooth you want it. The emery polish wheel does a good job by itself though if its all you have.
Air Compressor
Air Die Grinder
Air Spray Nozzle
3/4" Drum Sand Rolls - (60 grit I believe and I used 4 total although I only had 5 so I used each one for a while and flipped them once half of it wore out on the ridges your grinding down.)
2" Emery Polishing Wheel - (Its all I had to polish at the time and I will be going back with 500 - 1000 grit sand paper and re polish for a mirror finish... otherwise its plenty smooth enough... its as smooth as stock surface if you ask me)
I believe this takes less time with air tools vs the dremels... but that should be expected. Either way it will work... just take your time and sculpt it down feeling with your fingers until it feels smooth and at the same angle as the sides of the TB.I stayed about 1/4 of an inch away from the TB Blade... and just brought the two ridges on the top and bottom of the TB down to create more of a circle instead of the stock oval shape. You need to stay away from the area close to the TB blade when close because minor changes in this area will scrap your TB because of idle problems. The TB blade closes and makes a pretty tight seal only allowing a set amount of air through. The amount of air let through is what determines your idle. Take material off in the area 1/4 infront, behind or directly under where the TB blade sits closed and chances are your going to be buying a new TB. Your trying to eliminate the ridges just outside that danger area and transition as smoothly as possible into that area without every touching it.
Additional Options
1. Knife edging the TB blade
I personally didnt do this because I felt it was pointless and I knew if I screwed it up it could cause idle problems. K.I.S.S. (Keep it Simple Stupid) is a good way to think about this.
2. Halfing blade rod
EDIT: Not a good idea, has been proven to cause issues from stress put on the half shaft while modifying it. Can cause codes, improper idle etc. Best to stay away from this... although it can be modified correctly without these issues... but dont trust just anyone to do this. Most like myself will tell you that the risk isnt worth the rewards or possible issues later on down the road.
3. Opening up the backside of the TB where it makes contact with the intake manifold.
EDIT: Very possible to do by hand... it just requires a very steady hand familiar with the job to ensure the "critical" area isnt altered... causing codes/idle issues. Probably not something to do yourself unless you know exactly what to do. Ive successfully done it multiple times now with a specific method to significantly reduce chances of scraping the TB.
Tools I used... ( you can substitute different size sand rolls or even use flapper wheels if you like. I just used what I had at the time and it worked fine. You might consider using some 36 grit sand paper for the rough work and then come back with some 60, 120, 200 and so on and so on depending on how smooth you want it. The emery polish wheel does a good job by itself though if its all you have.
Air Compressor
Air Die Grinder
Air Spray Nozzle
3/4" Drum Sand Rolls - (60 grit I believe and I used 4 total although I only had 5 so I used each one for a while and flipped them once half of it wore out on the ridges your grinding down.)
2" Emery Polishing Wheel - (Its all I had to polish at the time and I will be going back with 500 - 1000 grit sand paper and re polish for a mirror finish... otherwise its plenty smooth enough... its as smooth as stock surface if you ask me)
I believe this takes less time with air tools vs the dremels... but that should be expected. Either way it will work... just take your time and sculpt it down feeling with your fingers until it feels smooth and at the same angle as the sides of the TB.I stayed about 1/4 of an inch away from the TB Blade... and just brought the two ridges on the top and bottom of the TB down to create more of a circle instead of the stock oval shape. You need to stay away from the area close to the TB blade when close because minor changes in this area will scrap your TB because of idle problems. The TB blade closes and makes a pretty tight seal only allowing a set amount of air through. The amount of air let through is what determines your idle. Take material off in the area 1/4 infront, behind or directly under where the TB blade sits closed and chances are your going to be buying a new TB. Your trying to eliminate the ridges just outside that danger area and transition as smoothly as possible into that area without every touching it.
Additional Options
1. Knife edging the TB blade
I personally didnt do this because I felt it was pointless and I knew if I screwed it up it could cause idle problems. K.I.S.S. (Keep it Simple Stupid) is a good way to think about this.
2. Halfing blade rod
EDIT: Not a good idea, has been proven to cause issues from stress put on the half shaft while modifying it. Can cause codes, improper idle etc. Best to stay away from this... although it can be modified correctly without these issues... but dont trust just anyone to do this. Most like myself will tell you that the risk isnt worth the rewards or possible issues later on down the road.
3. Opening up the backside of the TB where it makes contact with the intake manifold.
EDIT: Very possible to do by hand... it just requires a very steady hand familiar with the job to ensure the "critical" area isnt altered... causing codes/idle issues. Probably not something to do yourself unless you know exactly what to do. Ive successfully done it multiple times now with a specific method to significantly reduce chances of scraping the TB.