Basically, how far should you 'throat' down the manifold..? I've taken the rim back to the soot line/gasket then blended around a further 10mm making it as smooth as possible.

There's a web between the two tubes that's very rough, is it OK to work this a little..?

Finally, is it worth 'polishing' deeper into the pipe work..?

As a side note, the diameter of the opening into the manifold was ~39mm. It's now ~44mm tapering back to original diameter.

Pics for evaluation:

http://i14.photobucket.com/albums/a3...0657Medium.jpg
http://i14.photobucket.com/albums/a3...0656Medium.jpg
http://i14.photobucket.com/albums/a3...0655Medium.jpg
http://i14.photobucket.com/albums/a3...0652Medium.jpg

 

???

 

Go down as far as you can go, the deeper the better.

At the minute looks like you have a big chamfer IYSWIM, try and get a narrower angle.

If you can get tho the bridge its worth smoothing and knife edging it - every little bit helps and you may as well while its off

 

My ported headers go a lot deeper down than what you have done so far.

Keep working at it as my bolts kept seizing when i had to remove off again and again.

 

I've removed a lot of the chamfer now and it's much smoother, just need a half round grinder bit to go deeper without 'gouging'..!

what I've been doing is feeling with my finger for any ridges/bumps etc and working them out. It's quite therapeutic really..!

The hardest part was removing the heatshield brackets. A real pita with loads of elbow grease..!

Thanks guys.

 

Latest.....

Better, but still a little more chamfering (yellow markings) and deeper:
http://i14.photobucket.com/albums/a3...0674Medium.jpg
http://i14.photobucket.com/albums/a3...0671Medium.jpg

Cross pipe (awkward due to steel tube):
http://i14.photobucket.com/albums/a3...0673Medium.jpg

 

Finished.... marks out of 10..?

Quite pleased with end result (need to spray paint them later). However, it's not as easy as you think, Harvey certainly earns his money..! lol. You want to see the state of the garage floor..!

Oh and BTW who said 15' of wrap would be enough to wrap them properly..!!! More like 15m..! I actually used 30' which was just enough..!

http://i14.photobucket.com/albums/a3...0731Medium.jpg
http://i14.photobucket.com/albums/a3...0728Medium.jpg

Wished I'd have posted this in 'Projects' now..! Any chance of a move mods..?

PS I'll probably end up doing the same with my original headers when these get put on, so if anyone fancies a set (as above) at the right price let me know..?

 

looking good mate.nice job.let us know how it feels when fitted.