Checking inlet manifold port alignment.
Discussion
What clever tricks do people have to match up the inlet manifold to the head ? The inlet ports on my head are plainly bigger than the manifold, they are in fact slightly bigger than the standard gasket, having a step change can’t be helping so dremmel in hand I plan to adjust the manifold and gasket so it is a nice smooth transition. Plainly I can make the gasket fit the head and then make the manifold fit the gasket but other than sticking a looky round corners thing down the hole how can I check they actually line up. Best thing I can think of is to fit the manifold with some carbon paper in place of the gasket and see where it leaves a mark, if any.
Well, it sounds like you have a pretty good grasp of what port-matching, or gasket-matching, is all about. You should probably match to the part you have the greatest trust in. Are the heads aftermarket? Have they been professionally ported? Is the manifold a CNC finished piece?
Be careful not to enlarge either the ports, or the manifold runners too much. Port volume is important to velocity, velocity to cylinder filling. This all plays with where your rev band will be. Coordinate all with forethought.
One other option, that is very costly, is the extrude hone process.
What other modifications have you made, or are you planning?
B
Be careful not to enlarge either the ports, or the manifold runners too much. Port volume is important to velocity, velocity to cylinder filling. This all plays with where your rev band will be. Coordinate all with forethought.
One other option, that is very costly, is the extrude hone process.
What other modifications have you made, or are you planning?
B
I use card and blue to make a template. Make your own very accurate alignment marks and ensure the card is the same thickness as the gasket you intend to use. Once you have your templates of the existing components you can sit down with a cup of coffee and work out the best cutting plan without risk 
Laying a pattern on each side of the joint allows you some visualization of the 3d flow as well. So you can see the angles / shapes to cut behind the face, which can affect the final shape (chicken & egg IYSWIM).
Just transfer the final solution to the metal by scribing the outline and cut away.
Laying a pattern on each side of the joint allows you some visualization of the 3d flow as well. So you can see the angles / shapes to cut behind the face, which can affect the final shape (chicken & egg IYSWIM).
Just transfer the final solution to the metal by scribing the outline and cut away.
Also, if you match to a readily available, high quality gasket, you'll be able to re-order that part# and have it match again. There's no point in putting in a ton of work, and then order a different gasket next time you have the thing apart. A different manufacturer's gasket can be as much of an obstruction as the step you're working to eliminate.
Are you only matching, or doing more extensive port work?
Are you only matching, or doing more extensive port work?
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