How to port and polish a turbo exhaust housing

I'll fill this in later. The "book" I typed in this field before didn't save. Come back later if you want to read more about the theories behind porting and polishing.

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Porting an eBay 20g turbocharger
The price of this turbo will make it a popular purchase, so I figured I'd air out some tech about ways to improve it. This thing is not for everybody. I wouldn't feel comfortable bolting it on my car the way it comes out of the box. I could complain about its flaws except that so far absolutely none of them have been a deal-breaker for me. To me it's like an empty canvas. I promise to eat those words if it happens, and share my poop. Usually I can easily correct these flaws myself and so can you. BUT! If this thing turns out to perform well with what I do to it... It could easily be a cheap, quick ticket to an 11-second car. Something you could do with a free running 1g, a hacksaw, and about $500 worth of fuel upgrades. Yeah, that would be ridiculous, and I'm bolting it onto a well-modified car... But that being possible speaks volumes for what a DSM can really do. This is no big deal to me. I'd rather guinea pig my car for you in HD so you guys can decide whether or not you'd spend your money on this. Really it's an experiment because this isn't my daily-driver, and it contributes to building a better Colt. Tools I used involve: Scratch awl Milwaukee model ???? 1/4" straight-shaft electric DIY grinder Cone and ball-shaped double-cut burs 180 grit high-speed flap wheel Dremel with a flex-shaft and a tiny 320-grit flap wheel a zip tie 10mm combination wrench tiny flat-blade screwdriver (00) for the e-clip on the wastegate compressed air





Cylinder Head 204 - Porting & Polishing
This is a first-generation 1992 1.6L Hyundai Elantra small-combustion-chamber head. Thats what it is. It's a J1 Elantra cylinder head. Good luck finding another one like it. (read more)... In Cylinder Head 106 I talked about the mainstream porting theories as they are discussed. We looked at a cylinder head that I have thousands of dollars of professional work performed on, and a bone-stock second-generation head that I didn't port. In this video I just might do something you haven't seen done before. For some, that may be uncomfortable. The port and polish job I perform here is what I think will work best for my current build. This is not an extreme killer port job. What will be different here is where port textures are concerned, I will be following the advice of a reputable source that will remain un-named. You're free to port yours differently than I do in this video, and I give you that out, around the 20 minute marker. The Hyundai is far from being an ultimate-performance build. It's a $400 box of scraps with nothing but time invested. It's perfect for this video. My finished product WILL be an improvement over what I had. I don't yet have access to a flow bench. I still have an achievement to un-lock. As far as you should be concerned with the techniques I employ... without flow numbers there is no evidence of what this will do, but we will gather lots of info from dynp sessions and drag strip time slips. If I could test it on a flow bench, I would. There are MANY, and when I say many, I mean thousands of flame war mongering pirates floating around on rough seas with a hair trigger cannon finger itching to fire if you port a head any differently than what the herd mentality says to do while porting a cylinder head. I cover the herd mentality because it has merit. It's been tested. Tried and true. But I don't follow it to the letter of the law. I'm definitely not here to de-bunk it. I would port a cylinder head differently for each build based on how that engine was used. There's an extremely valid reason why relating to air speed. It's not the texture of a port that maximizes the effect of fuel atomization, but the velocity of the air running through an x or y sized valve. The driving factor in this is the piston speed. I'm not going to give you the technical information, but will refer you to information about the Lovell factor. There's a better description of this in the links below, and even a calculator to help you find your engine's sweet spot. Why the Lovell factor is important: https://www.highpowermedia.com/blog/3346/the-effect-of-valve-size Lovell gas factor calculator: http://www.rbracing-rsr.com/lovellgascalc.html Only people who have flow testing equipment know for sure what really works and have the capability to produce a perfectly-matched port job for the ultimate performance build. Those guys know the definition of ultimate, and THEY are floating below the water Aegis-class submarines ready to blow your comment up if you don't know what you're talking about. They don't care if you're an armchair mechanic or a herd of pirates. I will say, they're zoomed in pretty close on me right now, and I'm expecting to take a few hits. My work will be tested based on Dyno and drag strip performance, and the results will be posted here. Fortunately, those kinds of videos are a WHOLE LOT EASIER TO MAKE!!!





Ball bearing turbos rule
Start up and idles





Polishing Aluminum (GSX is alive)
Tools: You need a big one that can run for long periods of time. Air tools are out of the question because the compressors that can keep up with air DIY grinders use the equivalence of 100 60-watt incandescent light bulbs while running. Mine uses that much power and it CAN'T keep up. I like straight-shaft electric tools because they use less power than air tools in order to do more work. They spin faster and generally have more torque. Electric drills don't have the RPMs needed to work efficiently because you need heat from friction for the polishing process. Cordless, fo'getaboutit. Bench grinders have plenty of speed, but don't make enough torque. Most bench polishing equipment is built primarily for production, not detail. If you have to polish large simple pieces, they're fine for that. The goal is to use a tool that is efficient enough on what you're polishing to make this seem less like punishment. Quality tools. Dremels are only good for grinding and sanding tiny detail stuff, but larger industrial DIY grinders with a .25" chuck are what you need. Power tools are only acceptable for polishing. Power sanding equipment doesn't have a random orbit and also doesn't leave a grain to allow you to gauge how deep to go, so you can't achieve a polishable surface by mechanical means. You'll also notice that sandpaper for orbital and belt stuff doesn't go beyond 320 grit and it's expensive. With a power tool you will inevitably leave marks too deep to remove by wet sanding with 220 grit. You will pay for cheating. Removing casting marks or rough cast with a flap wheel is not cheating so long as you remove all of the defects evenly and still thoroughly hand-sand the part afterwards. About Sandpaper: Anything goes below 220 grit so long as it's dry. You have to wet-sand everything higher than 220 grit, so both electric power tools and non-wet-sanding paper are ruled out beyond that point. The best finishes are hand-sanded in the crosshatch method shown in this video. If there are stubborn scratches that your sandpaper won't take out, go to a coarser grit and work your way back. Step up only one increment in grit with every grade of sandpaper available until there are no visible scratches in the surface. Skipping a grit will just mean you have to work 4x as hard to do the same work. So 220, 320, 400, 600, 800, 1000, etc... Depending on what grade of aluminum you're working with, you can sometimes get away with sanding the part only to 600 grit. To get the most out of a shine, you have to go beyond 1000 grit. The farther you go with the sandpaper, the less work it will take to polish and maintain. About Rouge: The black rouge, or emery compound, has an abrasive in it. It's also considered a cutting compound. It removes material and makes easy work of oxidation. Because it has an abrasive it can leave directional swirls in the finish that are visible in some lighting conditions. It's an extremely-coarse polish but in many cases can produce a brilliant shine. Brown rouge is a step between black and white. Though unnecessary if you're using black, brown is less aggressive while still having the ability to remove scratches and defects. You can also polish wood with it. White rouge is ideal for precious metals PLUS aluminum. It removes what a jeweler calls a deep scratch, but what an auto enthusiast may consider invisible. If there's a scratch that the black rouge didn't take out, white rouge won't do it. It will however, bring out the most reflective finish in aluminum that you can achieve mechanically. Jeweler's rouge (red) is not for aluminum. Neither is blue or green. Well... blue is universal supposedly. I haven't ever needed it and don't trust it. About polishing wheels: Polishing wheels come in different textures. For black rouge I use hard or triple-stitched flannel wheels. The more stitching, the harder it is. The soft wheels tend to disintegrate quickly. The harder wheels can contribute to swirl-effects in the finish when they become contaminated. Metal polish: I can't say enough good stuff about cheap-old Blue Magic metal polish. Brightens the best white rouge polish jobs and is really easy to work with. Mothers is good. NEV-R-DULL is an amazing product that lifts and cleans almost anything out of metal. Where to get supplies: You can buy rouge by the pound at truck stops. Lots of great polishing supplies can usually be found anywhere where you'll find the rigs. Ask a trucker. Also there's HarborFreight, Eastwood, PJ Tool & Supply, and lots of others. Everything's within google distance.




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