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Porting Boss Intake

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16K views 62 replies 15 participants last post by  DiMora  
#1 ·
I figured while my car is down right now, I'd port my boss intake. I've never ported anything, so I figured I'd give it a shot.

Went to lowes, bought a dremel with a low speed.
120 grit sandpaper drum
Carbide tipped cutter
Polisher

Stock port

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After carbide cutter. Sort of blending in the 2 pieces of plastic and the triangular pieces
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Using the 120 grit sand paper drum, taking more off the injector boss and corner triangular bumps.

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120 grit sandpaper drum

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Right now I'm polishing it to get it as smooth as possible.

I'm hoping I did it right and didn't take out to much

---------- Post added at 04:28 AM ---------- Previous post was at 03:19 AM ----------

This is after smoothing it out, still want to smooth it alittle more

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It looks alittle rough in that picture, but it feels smooth. Like I said, going to keep smoothing it out til it's like glass.

I didn't really port the intake, more so just trimmed down the injector boss and the triangular shaped pieces on the corner at the end of the runner.
 
#37 ·
Okay, so idk how to view torque on the dynojet run viewer?

Here it is.

Boss vs ported boss

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Regular boss peak rwtq was 373. Ported boss was 379rwtq. So +11rwhp and +6rwtq.

Just for shits and giggles, added my best stock intake Dyno run

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Stock intake owns til 5500rpm, then boss rapes. If it wasn't for close gear ratio mt82, id keep the stock. The lowest my shift point drops is 5500rpm, where the boss takes over. Once I have slicks, I'll be leaving around 6000-6500rpm, the car won't be below 5500rpm. So boss IMO works best for my app.
 
#39 ·
Okay got torque on the graph.


Boss vs ported Boss

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Stock intake vs Boss vs Ported Boss intake

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#40 ·
Did you change the little gear thingy majig rpm reader thingy.

I dont remember what its called... high rpm pulse something.....
 
#42 ·
That plate that goes between the flywheel and crank? I kept the one that was already there.
 
#44 ·
I did not. I'm going to do it over winter. Plan is

Remove fins
Port some (not much meat there to work with)
Smooth out throttle entrance
90mm Throttle body
4.5-4" cold air intake. 90mm is 4", so I figured a 90* silicone reducer going from 4" and opening to 4.5" and using 4.5" aluminum pipe to make an intake.
Re-tune/Dyno

I think that should be worth 10-20rwhp.

If I'm not happy with it, I'll be doing a CJ intake, and a 110mm monoblade TB with a custom 5" intake.
 
#45 ·
Shaun sent me a tune, adjusted the MAF curve alittle and added a degree of timing. I'm going to re-Dyno probably this weekend. Just curious to see if it picks anything up. Guy charges $50 for 3 pulls but he's a good guy, he'll usually give you an extra pull or 2. So for $50, might as well!
 
#47 ·
Car feels great. Clutch pedal is nice and light, all together car feels amazing. Just need to get the neutral profile relearn done. And I'll be good.
 
#48 ·
#50 ·
YES! 3.73's lol. And headers... And suspension... And slicks. I just picked up 47lb injectors off my buddy for cheap. So I'll be running e85 in the spring time :)
 
#52 ·
Most likely ARH. Unless JPC comes out with new ones. Was gonna go with Kooks, but want a full length header... And especially one that clears the trans for removal.
 
#55 ·
For sure. Why I'm hoping they start making them again.

Did he say the new tune was required? Just kinda wondering if I can do this with my Boss without getting it tuned from him or if it is going to act funny.

Was yours driving fine else wise? I get making the changes because you can and should, just curious.
Not required, I asked him to check it over to see if anything could use any changes. Every little bit counts.

And yeah, everything else is great. Normal driving , cold driving, wot etc...
 
#57 ·
So ended up going to the Dyno today to compare, since Shaun sent a tune.

First pull made 445/390. 2nd made 450/395.

Good weather lol. Ended up loading in the other tune, made 445rwhp 2 times. So tune picked up 5rwhp and some torque.
 
#60 ·
Thanks. Yeah, I cant tell if the weather actually picked up 20rwhp (sae corrected) or if its a mix between the tune, and maybe the car was actually misfiring?? Car through misfire in cylinder 4 and 3 I believe. Cause my buddy Evan has a Boss, he made 450rwhp last time, this time made 450rwhp again lol. So I cant tell.... Anyways heres the dyno sheet. Idk why hp/tq is crossing at 5900rpm... At the dyno it crossed at 5250.

---------- Post added at 03:37 PM ---------- Previous post was at 03:36 PM ----------

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Ported Boss vs ported boss RETUNE

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Same run, showing weather conditions

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So idk, I'm confused lol
 
#62 ·
Ohh got ya! I'll have to **** with it later on

---------- Post added at 06:46 PM ---------- Previous post was at 06:36 PM ----------

Btw, was talking to Shaun over at AED... He said he to was down 20whp without a neutral profile relearn... And gained it back (2mph also) once it was performed.. So I guess it's not a fluke