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audidrvr
07-05-2005, 12:09 PM
I searched the archives but there doesnt seem to be a lot on this other than look at mine kind of stuff. I am wondering what the easiest/best way is to polish the intake manifold. I really dont want to hand sand for a week to get the finish. What kind of sanding wheels would I need to use to get through the roughest parts?

tia

Audimarc
07-05-2005, 12:22 PM
Extrude-hone it.

Quattrocket
07-05-2005, 12:27 PM
I attempted to polish it with my dremel, and it chewed right through the pads, so I just left it. It def has to be removed to do it properly and probobly needs to be done by hand. If search a little harder Im sure you will find something. A while back I remember someone did it and left instructions on how he did it. I believe it took him like a week to do it. It looked sweet.

Quattrocket
07-05-2005, 12:28 PM
found it. here ya go.
http://www.audizine.com/forum/showthread.php?s=&threadid=44845&highlight=intake+polish

jaredpgh
07-05-2005, 12:34 PM
Originally posted by 1999 Audi A4
Extrude-hone it.

I'll Second that!!

audidrvr
07-05-2005, 12:48 PM
Originally posted by Quattrocket
found it. here ya go.
http://www.audizine.com/forum/showthread.php?s=&threadid=44845&highlight=intake+polish

That was the best that I had found and for a hand job it is pretty good. I just didnt want to spend that much time. I suppose I have the time since it is leaking to much oil to drive though.
I said hand job, lol.

Quattrocket
07-05-2005, 12:52 PM
lol, hand job, huh huh huh. I hear ya, sounds like a shit load of work. mabey if you spend 12 hours a day for a weekend you could have it done quicker???

audidrvr
07-18-2005, 12:56 PM
wow, sanding this is a lot of work, I am having a hard time getting the bottom of the intake runners sanded.

Anyone know of a good dremel grinding stone? The one I had grinded off faster than the metal.

alen
07-18-2005, 01:54 PM
did somebody say they don't enjoy a week-long hand job? [:D]

kam1200
07-18-2005, 04:18 PM
You can just get it coated to get a similar look. Not quite polished to bling bling, but it will look smoother and alot nice than stock.

skold
07-18-2005, 05:26 PM
best way to poish anythign is with sanding blocks, you can get at local hardware stores, and it takes forever. first start off with 40 sand the whole thing, then go to 80, 120, then 340, then 600 800, and hten like 2200, and then youll need a polishing cream and a drill with a buffing ball on it.

but when you polish things it messes with the cooling aspect of casting, so your best bet is to get it powdered coated in "ceremic", will cost you about the same no matter what way you go. i used to polish everythign on my rx7.

here is a guy that did some of my stuff, he is super good, and prices are right too.

http://www.realcoatings.com/

audidrvr
07-18-2005, 05:30 PM
I wasnt going to use polishes actually, I am just trying to make it smooth and shiny I guess. Is the ceramic coating youre talking about a clear coat? That is sort of what I was thinking.

I started sanding with 60 I think, but it is hard to get all of the small stuff.

skold
07-19-2005, 08:33 AM
so its not a clear coat. go to that site and then car pic, 1st page last pic, that front cover is cermeic/

audidrvr
07-19-2005, 08:57 AM
thats cool, but not exactly what I am going for.

goody6691
07-19-2005, 10:04 AM
it took me four hours just to polish a flat, smooth piece of alluminum. maybe a high-speed tool like a DA would cut down alot of time.

Audiman78
07-19-2005, 02:14 PM
I meet the guy who polished it at High School Challange at Maple Grove in PA he was the one who told me about Audizine!

freeskiwp
07-19-2005, 09:15 PM
wire brush attachment on a drill perhaps? maybe you could get in all the little creases and shit with the wire brush..

audidrvr
07-19-2005, 09:54 PM
Originally posted by freeskiwp
wire brush attachment on a drill perhaps? maybe you could get in all the little creases and shit with the wire brush..

I tried that and it helped but wire brush only buffs the metal and doesnt really take away much of the roughness.

Audiman78
07-20-2005, 06:36 AM
The guy who did it took of his Intake Manifold and used sandpaper and started with like 80 and got down to 220 and by then it was shiny! It took him a while but it was worth it!

onemoremile
07-20-2005, 08:06 AM
i'm using an aluminum burr with an air compressor to smooth out the casting lines and gasket match it.
the grain is from sand casting the part and that is getting knocked down with a DA sander and various grits. the area between the runners will get hit with flapper wheels.
i started doing this by hand one day and gave up on it. waaaay too much work for such little reward. with power tools it shouldn't take long at all.
i'm doing this to an extra manifold. i going for a nice smooth satin finish. after swapping it onto the car i may do gloss black powdercoat of paint on the original one. maybe just sell it.

audidrvr
07-20-2005, 12:08 PM
yeah, I am thinking i am going to get a good dremel grinding stone and grind down the cast lines and just take off the worst of the coarse texture.

ModifiedA4
07-20-2005, 01:28 PM
i think half the people in this thread are talking about polishing the inside of the manifold, while the other half is talking about the outside.

funny stuff.

audidrvr
07-21-2005, 07:45 AM
I know, but I am working on the outside and a big thanks to those that have been giving me input on that.

I grinded down one of the casting lines and will continue with the rest sunday when I pick up some more attachments. Maybe by the end of next week I will be done and can post a pic of it.

ModifiedA4
07-21-2005, 07:58 AM
Originally posted by audidrvr
I know, but I am working on the outside and a big thanks to those that have been giving me input on that.

I grinded down one of the casting lines and will continue with the rest sunday when I pick up some more attachments. Maybe by the end of next week I will be done and can post a pic of it.

hey what ever floats your boat...personally, i think putting that much time into polishing the outside of the manifold is a major waste of time.

make sure you clear coat it afterwards or all your work will be for naught after a road salty winter.

audidrvr
07-21-2005, 10:03 AM
I dont really have to worry to much about salty winter, and I do plan on coating it with something, will figure that out when I am finished.

From my understanding the the inside flows fine for a ko3, but if I new of a place that could do the inside and port match it I would probably have that done too.

Dont you want some turbulance in there? I read somewhere that if it is to smooth you can have adverse results.

schearer225
07-21-2005, 10:57 AM
I polished my manifold up by hand. i was already going to install a evo heatsheild so i just decided to polished it while i was there. If you really bust ass and try to do it, it can be done in 2 days but you got to really do some hardcore sanding. i would stay away from any type of power sanding tools, i started to use one and it like would skip and leave bigger gashes in it. if you buy a sanding block for the larger sections it should go pretty easy. if you have any questions about polishing it while you are in the proccess just PM me and ill try to help out [:)]

SoFresh
12-16-2006, 01:00 AM
Couldnt you just paint this with a "chrome" or "aluminum" colored high-heat paint? Just a thought, because I was wanted to do what Offroader did with the wrinkle paint on the valve cover, and figured I might as well then also paint this with chrome high-temp paint, and also another question, what about the intake manifold, its all a rusty color... couldnt you paint that as well with high-temp paint... or is that not good for it? Will the high-temp paint let the rust show through? Anyone done this beofre?

pac1085
12-16-2006, 06:44 AM
Couldnt you just paint this with a "chrome" or "aluminum" colored high-heat paint? Just a thought, because I was wanted to do what Offroader did with the wrinkle paint on the valve cover, and figured I might as well then also paint this with chrome high-temp paint, and also another question, what about the intake manifold, its all a rusty color... couldnt you paint that as well with high-temp paint... or is that not good for it? Will the high-temp paint let the rust show through? Anyone done this beofre?

I did that...aluminum-colored & clear coat engine enamels by duplicolor.

It looked MINT at first...then after about a week it started turning YELLOW.

I had to take it off and sand blast it. Now it has a natural finish.

Powder coating it OTOH will work well.

soupie69uk
12-16-2006, 07:06 AM
I am not sure of the powder coating process but do the cover up all the inlets/outlets of the manifold when doing this?

NUISANCE
12-16-2006, 07:32 AM
Yes, if done right. They tape/plug the holes. Here's my powder coated set up-

http://img.villagephotos.com/p/2004-3/669711/BPDIC-k3.JPG

tamadrumr88
12-16-2006, 10:09 AM
http://forums.vwvortex.com/zerothread?id=2976454

my brother offers that if youre interested, pm me here or him on vortex if you need any more info

A4_2.8tuner
12-16-2006, 10:16 AM
my buddy polished the intake manifold AND valve cover on his 1.8t in hit GTI. looks awesome. He basically sanded it down, and then when it was smooth enough he took a polishing wheel and REALLY brought out the shine...not hard to do, just takes quite a bit of time and elbow grease. I polished the lips on my car, completely sanded down the clearcoat and started with 220, went all the way to 2000 grit then hand polished it...8 hours per wheel but it turned out pretty good.

here is a pic of my buddies engine. (gt3071r [eek] ) the engine is filthy in this pic, it really doesnt do justice.
http://myspace-760.vo.llnwd.net/00737/06/74/737644760_l.jpg

SoFresh
12-16-2006, 11:45 AM
^^^^ Thats where I got the idea to polish mine, I looked at your myspace/eurostatic page and saw that ride, gave me ideas. You say you polished your own lips on your rims, I curbed mine and they are already polished, I figure I can hand sand them down and make them look new all again. They didnt rust or anything? Did you put a clear coat on them?

smoothie
12-16-2006, 02:50 PM
i would hope your polishing aluminum rims..... aluminum doesn't rust

SoFresh
12-16-2006, 04:06 PM
^^^ good call, haha, thanks

onemoremile
12-16-2006, 09:12 PM
After gasket matching mine I used the burr to remove the casting lines from the outsides of the runners and plenum. I ended up just cleaning the whole thing up like that. I left it with the dimpled pattern a high speed aluminum burr leaves so it has kind of a raw finish. I figured that it would get nasty as hell like that so I put a couple coats of gloss clear on it. Before the clear it sparkled like a disco ball. the clear toned it down a lot.

http://i23.photobucket.com/albums/b397/onemoremile/IMG_2843.jpg

http://i23.photobucket.com/albums/b397/onemoremile/IMG_2839.jpg

http://i23.photobucket.com/albums/b397/onemoremile/IMG_2837.jpg

http://i23.photobucket.com/albums/b397/onemoremile/IMG_2851.jpg

http://i23.photobucket.com/albums/b397/onemoremile/IMG_2852.jpg

http://i23.photobucket.com/albums/b397/onemoremile/IMG_2954.jpg

http://i23.photobucket.com/albums/b397/onemoremile/IMG_2964.jpg

smoothie
12-17-2006, 01:12 PM
no prob high octane [up]

wow^^ that opens it up a lot. and good choice on the craftsman tools[up] my fav :) also that new reserve tank looks a hell a lot better! i would invest in one if i had the money for things like that... some day... (sigh) how much does one of them tanks run any who? if you don't mind me asking.

A4Rob
12-17-2006, 01:24 PM
Yes, if done right. They tape/plug the holes. Here's my powder coated set up-

http://img.villagephotos.com/p/2004-3/669711/BPDIC-k3.JPG

SOoooooo Nice

onemoremile
12-17-2006, 04:54 PM
how much does one of them tanks run any who? if you don't mind me asking.

30-35 bucks. A new cap is like 6 bucks.

smoothie
12-17-2006, 07:51 PM
heh... was bored snooping around on ecs. found it, thanks though[up]

did you take a run on the dyno after the porting? any significant gains in power?

smoothie
12-17-2006, 07:53 PM
i was bored snooping around ecs today, found it. thanks though[up]

did you take a run on the dyno after the porting? any significant gains?

EDIT: wow... my puter just smacked me upside the head... what the hell did i just do there?!?! sorry :P

NUISANCE
12-17-2006, 10:24 PM
SOoooooo Nice


Thanks bro. The good thing about powder coat is it cleans with alcohol and a micro fiber towel. It's not that much to do either. I think the IM was around $40.