Smoothed my 99/01 upper!!

[badblacklx]

Deleted egr flange and cast tube that runs on top of intake then welded up holes and smoothed. Also milled off some unnecessary mounting tabs and welded and smoothed the port that comes out of top of intake. Will also post finished pics with it painted.


Before example:

 

[MTBSully]

awesome. Paint it and post some installed pics

 

[badblacklx]

awesome. Paint it and post some installed pics

Thanks! Still have a few things to do then ill get it painted.

 

[Dilley]

what did you use to remove the flange and cast tube

 

[badblacklx]

what did you use to remove the flange and cast tube

Took the bulk of it with a bridge port mill and the rest with a flapper wheel.

 

[gimlach94]

Looking good man!! I'm in the process of doing the same to mine as well. I've been using a flapper wheel on a dremmel but omg it's so time consuming and tedious work to say the least

 

[badblacklx]

Looking good man!! I'm in the process of doing the same to mine as well. I've been using a flapper wheel on a dremmel but omg it's so time consuming and tedious work to say the least

Nice! Took like 15 min with mill lol. Remember if you remove egr tube it will expose two holes you need to weld up

 

[gimlach94]

Yeah I unfortunately don't have a mil. Might be able to get access to one. I spent a good 1.5 hours on it with a flapper wheel. Seems like a mill might be the way to go though

 

[badblacklx]

Just to clarify are you wanting to smooth and polish out casting flash or just remove unnecessary mounting boses and egr?

 

[gimlach94]

Both. I want to remove the egr and smooth the casting

 

[LT1Squirrel]

i remember my first time polishing something with a dremel, lasted about 3 minutes until i went to air powered

 

[gimlach94]

Lol I'll ever do it again! I burned my hands pretty bad because the dremel got so hot....at any rate I don't have a mil. I have air at the shop. Any ideas for really speeding up this process?