Bambam7

I have been running for a while now with no airpump, and therefore no functional aux port system.
I took the sleeves out, and the actuating rods, and noticed a positive difference at the high end- over having nonfunctional sleeves in place.
I decided I needed to go a pinapple style mod though.
I cut 1" off the end of each sleeve (to remove the crossbar), then, cut the sleeves almost in half lengthwise . I just extended the open part at the side of the sleeve all the way down- to open up the inner diameter a good bit.
Then I knife edged the leading edge of the sleeves. The main mod though, was to fill the end with a nice curved contour, using high heat 2 part aluminum epoxy putty.
Once molded to shape, (leaving a flat spot on the end just like the pineapple ones) I pressed them into place using some epoxy around the outside to keep them from rotating, and pushed them all the way in with an appropriate sized socket (since the sleeves are shorter than before)
I was actually VERY surpised at the difference this made. Very. I suppose since my engine is already ported, and flowing a lot of air, this improved things even more than it would on a stock engine!
No more flat spots, (before it felt like I had about 3 or 4!!) top end is much stronger, noticable in 1st gear especially... but overall from about 4000 rpms' up!

Also- as hard evidence, I'm getting a full 2-3% more airflow % off my S-AFC. (Thats how I gauge power increases)

HIGHLY recommended.

Just a little thing like this should have made this much difference... but wow, I don't really understand it.

Of course, if you want to keep the working 6 port system, you can't cut up yuor sleeves like I did, but you can still fill them, or get the pineapple sleeves- they are cheap.

Ni5mo180SX

nice, I was thinking about doing the exact same thing last night lol.

Node

iTrader: (1)

pictures pictures!

Bambam7

I know... I am going to borrow one sometime, to take pics of the turbo install, but I can't take pics of the sleeves nw for obvious reasons... I'll just photoshop some.

Roy James

sweet dude, good work! i am planing on trying something like this myself, exactly what kind of epoxy did you use? thanks man

Bambam7

I got it from Canadian Tire (eeek)
It's a 2 part epoxy- the type that comes on a stick that you knead together. It chemically bonds to aluminum, and is suitable for high heat applications.. can be sanded, drilled, etc.

rico05

Name of the epxoy?

Roy James

hey, im going to do this, but... i forget, how are they supposed to be lined up in the ports? its been a while since i have had mine in.. and i forgot hard about it the direction... thanks!

Silkworm

What concerns me about this is the potential for that epoxy coming loose. Remember that the sleeve is sitting ina very hot area of the engine, aluminum probably has a much different expansion/contraction rate from that epoxy. If you made the plug big enough, there's little chance of it falling into the engine, but loose isn't much better.

Welding is the only option that would be guaranteed, I would think.

Just my .02. Hope it holds together and proves me wrong.

PaulC

autocrash

pics? please?

Roy James

yeah, im kinda with Silkworm, that **** come loose.... sweeeeeeeeeeeeee, say "good bye" to N/A turbo project! hhmm... pics man pics

Bambam7

Ya... that's in the back on my mind.
It can't go into the engine unless it breaks up into little pieces... since the actuall glob of epoxy is wouldn't fit though the port.

It is an aluminum carrying epoxy, so there is lotsof actual aluminum embedded in the media. I'm sure the coefficients of expansion isn't that different. Also- the sleeve is fit pretty damn tight into port (more high heat epoxy around it).

I am going to examine them in a few weeks. I may not be able to get the sleeves out but I will look inside them with a mirror and light.

In retrospect, I should have just inserted the sleeves without adhesive on them, and just put a dab of loctite on the end or something, or even bend out a small section to create enough friction to hold them in... Oh well- their in there now!

Actually, they aren't in THAT hot of an area.. they are constantly getting cool air flow. The hottest the housing in that area could be is the temp of the engine coolant, but it's probably noticably cooler because of all the intake air.

It is supposedly good to 400 degrees F. Sounds enough for me!

I am still loving the results....

Roy James

word man, it think you are set, ill be making some of my own, once i lean my **** the hell down, jesus. have phun!

Bambam7

Here's the diagram of what I did. I cut out the section outlined in red, and also cut whole end of the sleeve off, about where the line is....
You can see how the sleeve is much thicker on either side, reducing the inner diameter... I cut one side of that out, and ground the other side thinner.
And where you see the metal insert on these, of course is epoxy on mine.

pp13bnos

iTrader: (1)

2-3% more air flow huh? I'm realy tempted to come to the dark side of the 6 ports...hmmmm. Maybe its time i go back in there, and do some serious porting to the lower intake.....get rid of the rod.....and its bump. I could see some serious hp gains just from reducing the size of the 6 port actuator rod....but to eliminate it all......Time to fire up the old mini-diegrinder.

CJ

autocrash

I think my 6 ports are busted...

Roy James

hhmm.. what about JB weld? --shrug--.. just an idea, i went to lowes and Home Depot and couldnt find any epoxy puddy and deffinatly couldnt find any that was just for aluminum, but.. i do have some JB weld, thanks

HAILERS

Drill a hole thru both pieces and countersink both sides of the hole. Hammer in an aluminium rivet and double flush both sides. Beats the possibility of a chunk of epoxy coming out.