So I uhh got a little carried away last night

[slow4dr]

I bought a stock intake manifold from a guy in Nor-Cal with the intent of porting & polishing it. After receiving it and looking it over I realized quickly that other improvements could be made. The under side of plenum is concave limiting its overall volume. I have seen the 2JZ guys add a few cubic inches to their stock manifold and pick up 20-25 WHP so I started thinking I could make this area straight instead of concave. This could easily add 10-15% of volume to the plenum as well as give a much more straight shot afer the throttle body. This will also allow me to open up the back side of the manifold so I could actually port & polish each runner all the way through.

After cuting away at the lower part of the plenum I quickly realized that even with it removed I still won't be able to fully port the whole runner. Next thing I knew the whole damn plenum was removed with just one part of it holding the throttle body adapter in place. After this was removed I found that a lot of improvement can be made in the inlet area of the runner. The casting was very shitty in this area. It had uneven port volume apparent to the naked eye with cracks & pits all over the place. As I was cleaning all this up I was contemplating how I was going to make the new plenum. I have some ideas but it will closely resemble this style.

http://nissaninfiniticlub.net/photopost/data/500/4316RBsig.JPG

I took some pics last night of my progress but we-todd-did is still down so I couldn't upload them. I will find a new way to host them this weekend and post them up.

[punkrokdood]

this is awesome jason... one thing though, i've heard that the concave area is for clearance issues with the alternator, but i dunno for sure... can't wait to see the finished product...



I took some pics last night of my progress but we-todd-did is still down so I couldn't upload them. I will find a new way to host them this weekend and post them up.
you should get a photobucket account, its free, and its not down all the time like wee-todd-did :thumb:

or email them to me, and i'll host them... i have my own domain, not sure how much bandwidth, but i'm sure i won't be using it up :lol:

[slow4dr]

It is actually the starter that has clearance issues but yes I am accounting for that.

I knew I should have e-mailed the pics to my work e-mail last night. :knife:

[punkrokdood]

starter, that's what i meant... i knew it was starter or alternator... I'm always mixing them up when i try to remember things :ftard:

btw, i DO know the difference :lol:

[SinisterSRT4]

starter, that's what i meant... i knew it was starter or alternator... I'm always mixing them up when i try to remember things :ftard:

btw, i DO know the difference :lol:I was like isn't the alternator near the turbo :lol:

[svt2srt4]

that new intake sounds like its going to be badass...still can't wait to see vid of the 2jz nova racing...:thumb:

[liteshow]

Also remember the stock mani is made in a manner to get equal amounts of air to each cylinder.

[punkrokdood]

75 mm t/b too???? :lol:

[slow4dr]

Also remember the stock mani is made in a manner to get equal amounts of air to each cylinder.


I can guarantee that each runner doesn't flow even close to the same #'s from the factory. The plenum which is all I am changing has very little to do with runner flow anyway.

[slow4dr]

75 mm t/b too???? :lol:


I am going to remove the bottle neck after the adapter. The area where the OD of the adapter slides into the ID of the manifold will be removed so whatever size the ID of the manifold is I will continue that all the way into the plenum.

[punkrokdood]

I am going to remove the bottle neck after the adapter. The area where the OD of the adapter slides into the ID of the manifold will be removed so whatever size the ID of the manifold is I will continue that all the way into the plenum.
nice...

will you be "offering" this, or is it a one off custom thing? you gonna need a custom cold pipe, or direct bolt in?

[slow4dr]

nice...

will you be "offering" this, or is it a one off custom thing? you gonna need a custom cold pipe, or direct bolt in?


I might make a few of these if testing proves them to be beneficial. :thumb: They will be a direct bolt-on.

[Broken5hift]

USE PHOTOBUCKET MORON

[slow4dr]

USE PHOTOBUCKET MORON


blah blah blah, yeah I know :ftard:

[turbo_protege5]

GET er' DONE!!!!!!!:bs:

[Broken5hift]

blah blah blah, yeah I know :ftard:

if i have to tell you one more time im gonna start asking you if your gonna drift your car

[blackbird]

It'll be interesting to see what you come up with. The stock manifold is a fairly nice design, but there's probably more to be gained at some of the big turbo power levels. For anyone who hasn't seen one of the manifolds off the car, below are some pictures of the one on my car. While it was off I did some mild work to it, but I'm going to end up doing more if/when I go through the rest of the intake path and head.

These are some pictures of stock. You'll notice quite a bit of casting flash in some areas. Also note that the inside diameter of the throttle body spacer does not line up very well to the manifold and leaves a lip (and is like this on all the manifolds I've checked).

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/stock_manifold/intake_inlet_floor.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/stock_manifold/intake_inlet_roof.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/stock_manifold/intake_runner_port.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/stock_manifold/port_roof.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/stock_manifold/port_floor.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/stock_manifold/intake_with_adapter.JPG


Below are pictures after I finished some work to it. A few things to note. The I.D. of the spacer now matches up with the intake manifold but in a few spots the casting of the manifold was uneven and already a little 'wider' than the spacer (camera flash/angle doesn't show it really well either). When I go with a bigger throttle body and spacer bore I'll also need to match it up again to ensure a turbulence free flow. Since it's off the car again I'm going to remove more of the hump below the fuel injector. That should allow me to open it and clean it up a little further into the runners. And unless the intake ports on the head get some work, they don't need opened up a great deal. The manifold gasket is absolutely massive compared to the actual port size.

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/ported_manifold/inlet_with_plate_side.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/ported_manifold/inlet_with_plate_bottom.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/ported_manifold/inlet_with_plate_top.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/ported_manifold/intake_inlet_bottom.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/ported_manifold/intake_port_bottom.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/ported_manifold/intake_port_side_close.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/ported_manifold/intake_port_top.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/ported_manifold/intake_ports_bottom_all.JPG

http://srtcentral.com/webfiles/misc/automotive/SRT4/engine/intake/ported_manifold/intake_ports_side.JPG


It should work reasonably well for the stock turbo, but I'd make some changes for an all-out racecar with a big turbo. To save a little on custom fabricating a completely new manifold I'd looking into opening up the runners to match the ports on the head and cutting off the stock plenum. Then match a tank-style plenum to the runners. For the throttle body I'd look into finding an OEM setup that could be used from another car/truck.

What was learned from the Turbo III (Chrysler's 16V 2.2L turbo) was used as a basis for the Neon DOHC heads, and you can see a similarity in design. Here's (http://www.rdiperformance.com/page4.html) a good link for some nice custom modified manifolds made for that engine (and the 16V 2.2L Chrysler/Maserati Cosworth here (http://www.rdiperformance.com/page2.html)). I also know who designed the intake manifolds for the PT GT turbo and I think he had a hand in the SRT-4 manifold. I'll see if I can dig up his contact info and try to find out if he has any suggestions on modifications for the bigger turbo's.

Also a good thread/read on throttle body and intake plumbing sizing from TD.com is at this link (http://www.turbododge.com/forums/showthread.php?t=105570). It has some good points to keep in mind when designing everything to work together. (And for flow consideration remember that the Turbo I, II, and IV engines used SOHC, 8V non-crossflow heads and aren't as efficient as the 16V heads; i.e. we have better efficiency and subsequently higher air flow requirements.)

[slow4dr]

Better late than never.

http://i41.photobucket.com/albums/e260/slow4dr/SUNP0004.jpg

http://i41.photobucket.com/albums/e260/slow4dr/SUNP0003.jpg

http://i41.photobucket.com/albums/e260/slow4dr/SUNP0002.jpg

http://i41.photobucket.com/albums/e260/slow4dr/SUNP0001.jpg

[slow4dr]

dammit

srtforums.com/forums/showthread.php?p=3066301#post3066301

[svt2srt4]

uuhhh...where is the rest of the intake manifold jason?

[slow4dr]

uuhhh...where is the rest of the intake manifold jason?


Misc little fragments all over the garage floor. :thumb:

[svt2srt4]

Misc little fragments all over the garage floor. :thumb:
so i guess tig welding aluminum will be in your future?:rofl: :rofl:

[slow4dr]

so i guess tig welding aluminum will be in your future?:rofl: :rofl:


:rofl: :thumb: Tig > me & left hand > me

[svt2srt4]

:rofl: :thumb: Tig > me & left hand > me
have you tigged aluminum before?...and are you saying you tig left handed ?..and if this is all yes then please post a video of you doing the intake and a pic of the disaster that will be the end result:thumb:

:rofl: :rofl: :rofl: :rofl: :rofl: :rofl:

[slow4dr]

have you tigged aluminum before?...and are you saying you tig left handed ?..and if this is all yes then please post a video of you doing the intake and a pic of the disaster that will be the end result:thumb:

:rofl: :rofl: :rofl: :rofl: :rofl: :rofl:


I have tried many times and my left hand just doesn't agree with it. A ssoon as I get the right hand and foot doing what I want the left hand is on vacation.

[blackbird]

http://i41.photobucket.com/albums/e260/slow4dr/SUNP0003.jpg

Boost leak or you've gone the N/A route?

[svt2srt4]

I have tried many times and my left hand just doesn't agree with it. A ssoon as I get the right hand and foot doing what I want the left hand is on vacation.
so you cant get your rod hand doing what you want?...if so you will be using that tig like a plasma torch on that soft ass aluminum you need to keep constantly adding rod or the weld will be shitty and look more like a valley instead of a even bead...aluminum is not forgiving at all and i have toasted a few projects myself before getting the hang of it...and i do this shit for a living...

[slow4dr]

so you cant get your rod hand doing what you want?...if so you will be using that tig like a plasma torch on that soft ass aluminum you need to keep constantly adding rod or the weld will be shitty and look more like a valley instead of a even bead...aluminum is not forgiving at all and i have toasted a few projects myself before getting the hang of it...and i do this shit for a living...

Yep, this is why I have the guys at work do it for me.

Boost leak or you've gone the N/A route?

I was thinking about cuting a hole in the hood and making it a ram air.

[punkrokdood]

Yep, this is why I have the guys at work do it for me.



I was thinking about cuting a hole in the hood and making it a ram air.
make sure you put a t-shirt or something over it so you don't get a bunch of dirt in the ram air scoop :thumb:

[Broken5hift]

you should go with individual throttle bodies

[slow4dr]

you should go with individual throttle bodies


HMMM, that's not a bad idea. Where's el-jefe when I need him? :rofl: it wouldn't be to hard to reroute the throttle cable and run some GSXR1000 throttle bodies.

make sure you put a t-shirt or something over it so you don't get a bunch of dirt in the ram air scoop :thumb:


I prefer silk stalkings.

[blackbird]

I was thinking about cuting a hole in the hood and making it a ram air.

You'd be fasterest! Screw a big turbo or any turbo for that matter. That's what I was told on a Hondah forum.

[Broken5hift]

ive also seen people put a collector on the TB and then mandrel bend tubes into each port at desired legnth (like headers) to maximize intake flow and volume. just a thought

[blackbird]

You talking like an early stock Quad 4 intake manifold?

[slow4dr]

A little update:

I have the sides, top and base of the plenum cut and I have been working on cleaning the ports up. I ran out of the proper tools on the porting part so I just left it for now.

http://i41.photobucket.com/albums/e260/slow4dr/wastegate008.jpg

http://i41.photobucket.com/albums/e260/slow4dr/wastegate007.jpg

http://i41.photobucket.com/albums/e260/slow4dr/wastegate005.jpg

http://i41.photobucket.com/albums/e260/slow4dr/wastegate006.jpg

[Ultimateone]

very cool.

[slow4dr]

The plenum is partially welded up. I had to bring it home tonight to make some of the T/B adapter pieces. I am hoping to be able to drop a WD40 can through the T/B opening into the plenum after it's finished. :lol:

http://i41.photobucket.com/albums/e260/slow4dr/wastegate015.jpg

http://i41.photobucket.com/albums/e260/slow4dr/wastegate013.jpg

Here is a good shot of how much wider this plenum is than the factory one.
http://i41.photobucket.com/albums/e260/slow4dr/wastegate016.jpg

[Ultimateone]

awesome work so far...

[westup]

bitchen man!! cant wait for results....damn


be sure to make me one when u are done.. thanks!!

cashish in hand ...j/k LOL

[slow4dr]

It should be finished this week. I don't think I am going to have patience to wait for a dyno before & after.

I think if I make any more of these it will be on a VERY limited basis.

[svt2srt4]

It should be finished this week. I don't think I am going to have patience to wait for a dyno before & after.

I think if I make any more of these it will be on a VERY limited basis.
good then you can just make mine and be done with it:jester:

[slow4dr]

I should have it finished by tomorrow but I don't think I am going to put it in until I have the S2 installed to make sure I have enough fuel.

I am not sure what I am going to do with the T/B adapter but I am contemplating removing the back section that slides in to the plenum.

http://i41.photobucket.com/albums/e260/slow4dr/snow003.jpg

http://i41.photobucket.com/albums/e260/slow4dr/snow004.jpg

http://i41.photobucket.com/albums/e260/slow4dr/snow005.jpg

[DJ2]

Lookin good!!

[westup]

holy big bore tb ready batman

[DJ2]

:lol: holy big bore tb ready batman
HAHAHA that should move some air huh??

[slow4dr]

The manifold is pretty much done all I have left is some basic clean up of some of the welds and make sure there isn't any left over slag inside. I am just waiting for a chance to get the adapter in the lathe to open it up the same size as the manifold. I have to take the manifold back to work next week so I can put it on the flow bench. BTW: The inlet I/D is 72mm's.

http://i41.photobucket.com/albums/e260/slow4dr/Intakemanifold001.jpg

http://i41.photobucket.com/albums/e260/slow4dr/Intakemanifold002.jpg

http://i41.photobucket.com/albums/e260/slow4dr/Intakemanifold003.jpg

[Pr3mium Brewed]

*drool*

That's awesome.

[el_jefe]

HMMM, that's not a bad idea. Where's el-jefe when I need him? :rofl: it wouldn't be to hard to reroute the throttle cable and run some GSXR1000 throttle bodies.

Heh. I have a set in the garage. My IM project is on hold, between the house, the 1st gen and the Harley I have no cash right now.

[mo'ssrt4]

Looks great jayson. I will have mine done soon as well. It will be a little differnet then yours. Dam i love the way it looks great job man.

[slow4dr]

Heh. I have a set in the garage. My IM project is on hold, between the house, the 1st gen and the Harley I have no cash right now.

:thumb: There's plenty room for ITB's.


Looks great jayson. I will have mine done soon as well. It will be a little differnet then yours. Dam i love the way it looks great job man.


Thanks Mo! I can't wait to see how yours turns out.

[mo'ssrt4]

Jayson the difference will be we are going to put a 4.5 inch pelum and it will not neck down, I wonder if there will be any cons to that. Reason we went with 4.5 inch is because maybe in the future we were thinking about putting little velocity stacks inside the pelum on each runner. Do you think that will be a good idea?

[turbo_protege5]

jason, that is just BADASS!!! great job bro!!!:thumb:

[slow4dr]

Jayson the difference will be we are going to put a 4.5 inch pelum and it will not neck down, I wonder if there will be any cons to that. Reason we went with 4.5 inch is because maybe in the future we were thinking about putting little velocity stacks inside the pelum on each runner. Do you think that will be a good idea?


:thumb:

I thought about doing mine like that but the throttle body just sits in the wrong place to do it the way I wanted to.

All the flow bench tests I have seen while using air forced into the plenum instead of being pulled the velocity stacks inhibited flow. I think for an N/A engine they are a good idea but I am still undecided on a turbo engine.

[slow4dr]

jason, that is just BADASS!!! great job bro!!!:thumb:


:thumb:

Thanks man!

[mo'ssrt4]

:thumb:

I thought about doing mine like that but the throttle body just sits in the wrong place to do it the way I wanted to.

All the flow bench tests I have seen while using air forced into the plenum instead of being pulled the velocity stacks inhibited flow. I think for an N/A engine they are a good idea but I am still undecided on a turbo engine.
Cool thanks jay. So you think having a 4.5 inch pelum and not necking it down will hurt anything or you think it will be fine? I can see the 4.5 inch pelum might be little too big for a stock turbo but I think for a big turbo it will be fine. Also having a 2.4 liter motor does need a bigger pelum compare to a lets say a honda 1.8 liter. My friend has a 4 inch pelum on his honda and he said he should go bigger because of the 2.4 liter, so we went with a 4.5inch pelum.

[blackbird]

All the flow bench tests I have seen while using air forced into the plenum instead of being pulled the velocity stacks inhibited flow. I think for an N/A engine they are a good idea but I am still undecided on a turbo engine.
For their function and how they work I'd skip them on a forced induction engine. But who knows. Weird things that don't make sense have been known to work in the past. :dunno:


For a N/A application Cosworth has a really nice manifold for the Duratec Focus's.

http://www.cosworth.com/uploads/1120583856450.jpg
http://www.cosworth.com/shop_item.php?productid=72

I'll have to see if I can dig up a picture of the internals. I know I've taken a few at some events last year.

[slow4dr]

For their function and how they work I'd skip them on a forced induction engine. But who knows. Weird things that don't make sense have been known to work in the past. :dunno:


For a N/A application Cosworth has a really nice manifold for the Duratec Focus's.

http://www.cosworth.com/uploads/1120583856450.jpg
http://www.cosworth.com/shop_item.php?productid=72

I'll have to see if I can dig up a picture of the internals. I know I've taken a few at some events last year.


It would be real nice to just take this one down and have a cast copy made. I love that bare casting look. I think a velocity stack that doesn't protrude into the plenum is the best deisng for a boosted application.

Cool thanks jay. So you think having a 4.5 inch pelum and not necking it down will hurt anything or you think it will be fine? I can see the 4.5 inch pelum might be little too big for a stock turbo but I think for a big turbo it will be fine. Also having a 2.4 liter motor does need a bigger pelum compare to a lets say a honda 1.8 liter. My friend has a 4 inch pelum on his honda and he said he should go bigger because of the 2.4 liter, so we went with a 4.5inch pelum.


I think 4.5" will work well with a big turbo car such as yours. If you can get the throttle body to line up I say go for it.


Here are some comparison pics I just took. I mocked it up on the car and so far so good. I didn't want to take any pics of it on the car yet because then everyone would assume I had it running and would have a thousand questions about how it is. The only thing left is to relocate the bung for the brake booster but everything matches up really well.

http://i41.photobucket.com/albums/e260/slow4dr/Intakemanifold005.jpg

http://i41.photobucket.com/albums/e260/slow4dr/Intakemanifold006.jpg

http://i41.photobucket.com/albums/e260/slow4dr/Intakemanifold007.jpg

http://i41.photobucket.com/albums/e260/slow4dr/Intakemanifold008.jpg

[mo'ssrt4]

god dam jay that looks fucking awesome. HOLY SHIT.

[punkrokdood]

It would be real nice to just take this one down and have a cast copy made. I love that bare casting look.

i agree SOOOOOOOOOOOOOO much...

i'd LOVE to see a cast version of that manifold... then again, you know how much i love stuff that looks stock :thumb:


great work though.... i can't wait to see that in the car, and see the gains :thumb:

[Neon8u]

Holy shit jason that looks real good! Nice job!

[el_jefe]

Cool thanks jay. So you think having a 4.5 inch pelum and not necking it down will hurt anything or you think it will be fine? I can see the 4.5 inch pelum might be little too big for a stock turbo but I think for a big turbo it will be fine. Also having a 2.4 liter motor does need a bigger pelum compare to a lets say a honda 1.8 liter. My friend has a 4 inch pelum on his honda and he said he should go bigger because of the 2.4 liter, so we went with a 4.5inch pelum.


Bigger plenum should give you better off boost throttle response. I wouldn't worry about velcity stacks either if your runner length is anywhere close to stock.

[mo'ssrt4]

Bigger plenum should give you better off boost throttle response. I wouldn't worry about velcity stacks either if your runner length is anywhere close to stock.
Cool thanks the runners will be stock, we are doing the same thing as jayson, just cutting the stock manifold and putting the pelum on there we are just going to bore the runners out a little bit.:thumb:

[StreetRaceGN]

Looks good:thumb: What are your thoughts on runner length/plenum shape relative to airflow distribution? We've had problems on other cars that required the use of modified plenum spacers, etc. in order to resolve airflow issues that affected per cylinder air distribution. We had to make per cylinder corrections via engine management to get even EGTs until we added the plenum spacer(after much trial/error on design). The plenum spacer was more of an inexpensive band-aid to go after the issue at hand, true resolution would have involved a plenum/lower intake/runner redesign.

[slow4dr]

Looks good:thumb: What are your thoughts on runner length/plenum shape relative to airflow distribution? We've had problems on other cars that required the use of modified plenum spacers, etc. in order to resolve airflow issues that affected per cylinder air distribution. We had to make per cylinder corrections via engine management to get even EGTs until we added the plenum spacer(after much trial/error on design). The plenum spacer was more of an inexpensive band-aid to go after the issue at hand, true resolution would have involved a plenum/lower intake/runner redesign.


I didn't change the runners so the plenum won't effect flow enough to make me worry about it.

[blackbird]

What are your thoughts on runner length/plenum shape relative to airflow distribution?
They had this exact issue on the older Chrysler Turbo I/II/IV cars. If you look at the calibration code they run different injector pulse widths to enrichen the mixture on a couple of the cylinders (that combined with poor coolant flow to a couple cylinders that ran hotter, so they also used the extra fueling to help control detonation). The manifold design used on the SRT-4 is good for packaging but not the absolute best for optimal equalized flow. But for a mass-produced factory design it works good enough.

[lunchbox660]

jason, one question for ya....since you have put so much work into this already, why dont you want to relocate the brake booster bung to a spot that is easier to get to? its a pain in the ass to get to it the way it comes stock, i thought this would be perfect chance for someone to make life a little easier in regards to this issue....just curious...im sure you have a good reason, i just dont know what it is...

joe

[slow4dr]

jason, one question for ya....since you have put so much work into this already, why dont you want to relocate the brake booster bung to a spot that is easier to get to? its a pain in the ass to get to it the way it comes stock, i thought this would be perfect chance for someone to make life a little easier in regards to this issue....just curious...im sure you have a good reason, i just dont know what it is...

joe


I haven't ever needed to take my booster line off so it wasn't even a thought in my mind. With the A/N fitting on there now I shouldn't ever need to screw with it.

[slow4dr]

The manifold is installed but boost leaks are owning me right now. I removed so much mating surface from the T/B adapter I am having a hard time getting it to seal up against the manifold. I have machined both surfaces flat and used some gasket sealer and it still leaks pretty badly. I am going to make a gasket and put it in next weekend, hopefully that will cure it.

I didn't get a chance to get it on the dyno so I guess I will just have to wait for the next track day.

[Ultimateone]

damn that sucks about the leaks, I bet the 70mm boomba TB would be sweet with your IM.

[blackbird]

A gasket with a little Hylomar sealant might work. Or worst case you could have it welded on.

[slow4dr]

A gasket with a little Hylomar sealant might work. Or worst case you could have it welded on.


If a gasket and sealant doesn't do the trick I will have it welded. That was the original plan but I got impatient.

[MChat]

Nice.

My car is currently having a new intake manifold built. I used the stock runners, but cut them off about 1" past those rib-things on the sides of the runners.

I've considered going with a 70mm throttlebody as well, but the Idle Air Control motor keeps me away from that route.

When you ported the runners, did you gasket match it on the head side? I'm wondering if there is enough material to do that. If not I may have some material added as I am considering having the head and intake matched to the gasket, which is quite a bit larger than the ports.

[slow4dr]

Nice.

My car is currently having a new intake manifold built. I used the stock runners, but cut them off about 1" past those rib-things on the sides of the runners.

I've considered going with a 70mm throttlebody as well, but the Idle Air Control motor keeps me away from that route.

When you ported the runners, did you gasket match it on the head side? I'm wondering if there is enough material to do that. If not I may have some material added as I am considering having the head and intake matched to the gasket, which is quite a bit larger than the ports.

The gasket doesn't match the head so I didn't match the manifold to it. I slightly cleaned up the manifold outlet but I didn't remove much meat at all. I don't think there would be enough meat there to open it up to match the gasket.