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Hand Porting Boss 302 Manifold (Help)

WildHorse

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Others have had good results with it and it will also match my 95mm throttle body
Those intakes are good OTB for 8k rpm. They're dry manifolds, so air is riding above the surfaces. If your opening it only to match your 95mm , I wouldn't rely on the O-ring.

JMO.
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tdstuart

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Those intakes are good OTB for 8k rpm. They're dry manifolds, so air is riding above the surfaces. If your opening it only to match your 95mm , I wouldn't rely on the O-ring.

JMO.
The goal is to smooth out the glue and edges, give it some more volume with a spacer, remove the inner supports to help with airflow, and open the inlet for the large tb.

Oring is completely removed with the 95mm throttle body. Still trying to figure out how I want to seal that as your typical paper/rubber tb gasket is too thin and leaves air gaps.
 

WildHorse

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Still trying to figure out how I want to seal that as your typical paper/rubber tb gasket is too thin and leaves air gaps.
RTV.
 

GregO

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That was my go to thought.
Two possible options,
Talk to Soler Perf. they offer a gasket solution when porting out the TB sealing gland.
Another option is calling Cometic Gasket and have them custom cut a gasket using one of their recommended gasket materials.
 

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tdstuart

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Two possible options,
Talk to Soler Perf. they offer a gasket solution when porting out the TB sealing gland.
Another option is calling Cometic Gasket and have them custom cut a gasket using one of their recommended gasket materials.
Thank you for the suggestions I’ll check them out!
 

AcceptableNebula

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Did you get to finish this project?
 
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tdstuart

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Did you get to finish this project?
Nope. Couldn’t figure out an easy way to make the spacer. My idea was to scan it and 3d print it but the phone scanning app was low quality and it was my first time ever touching cad software so it was a disaster. Did have something made and 3d printed but the fit was very rough and I stopped there.

If you want a cut open boss 302 I have one haha

I talked to a guy who does make these and he does not 3d print a spacer but instead uses some material to build up a spacer. He also does not cut it directly on the mold seam, he cuts above on the upper lid. Not sure what he uses to build the spacer he did not share.

I think if I had an actual hand 3d scanner and spent some real time to learn cad so I knew what I was actually doing it could have turned out decent. Just need a good epoxy to bond it all together. I am going twin turbo now so probably won’t finish this project any time soon if at all
 

AcceptableNebula

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Nope. Couldn’t figure out an easy way to make the spacer. My idea was to scan it and 3d print it but the phone scanning app was low quality and it was my first time ever touching cad software so it was a disaster. Did have something made and 3d printed but the fit was very rough and I stopped there.

If you want a cut open boss 302 I have one haha

I talked to a guy who does make these and he does not 3d print a spacer but instead uses some material to build up a spacer. He also does not cut it directly on the mold seam, he cuts above on the upper lid. Not sure what he uses to build the spacer he did not share.

I think if I had an actual hand 3d scanner and spent some real time to learn cad so I knew what I was actually doing it could have turned out decent. Just need a good epoxy to bond it all together. I am going twin turbo now so probably won’t finish this project any time soon if at all
I think those internal supports become very important when boosted. May be a blessing it didn’t work out. I have twins and am going to be changing from a Gen 3 to the Boss 302, which the port work will be extremely mild. Still investigating the Boost Proof methods.
 
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tdstuart

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I think those internal supports become very important when boosted. May be a blessing it didn’t work out. I have twins and am going to be changing from a Gen 3 to the Boss 302, which the port work will be extremely mild. Still investigating the Boost Proof methods.
Yes would not use the manifold for boost. Was only ever planning on it being na. When you go to that big of a throttle body you lose the oem oring and sealing the throttle body becomes an issue that I’m sure boost would push to failure.

I bought another boss manifold I did light porting on, just cleaning up the seams to help reduce any airflow disturbances. Didn’t take off enough material to worry about boost levels until I’m doing 25+ lbs which I don’t expect any time soon.

I am interested in how boost proof boss makers reinforce the manifold. It seems they keep it very hush hush tho
 

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AcceptableNebula

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Yes would not use the manifold for boost. Was only ever planning on it being na. When you go to that big of a throttle body you lose the oem oring and sealing the throttle body becomes an issue that I’m sure boost would push to failure.

I bought another boss manifold I did light porting on, just cleaning up the seams to help reduce any airflow disturbances. Didn’t take off enough material to worry about boost levels until I’m doing 25+ lbs which I don’t expect any time soon.

I am interested in how boost proof boss makers reinforce the manifold. It seems they keep it very hush hush tho
I talk about it a bit on my build thread. I have some theories and ideas. What was the spacer you were talking about? The throttle body?

https://www.mustang6g.com/forums/threads/2023-gt-premium-my-twin-turbo-build.187669/post-4462214
 
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tdstuart

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I talk about it a bit on my build thread. I have some theories and ideas. What was the spacer you were talking about? The throttle body?

https://www.mustang6g.com/forums/threads/2023-gt-premium-my-twin-turbo-build.187669/post-4462214
The spacer I was making was for the plenum. Just the cheapest plastic I could have 3d printed in decent detail from an online parts printer. It was a little warped but it was still off enough I got discouraged. For the throttle body I was going to see if something like rtv could hold up since the surfaces seemed to be so bad on the manifold after removing the oring that a simple paper style gasket didn’t seem to be viable. Again this was just for na.

Here is my prototype spacer I had

IMG_6175.webp
 

AcceptableNebula

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Cool idea for sure!
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