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  Topic Review (Newest First)
09-30-2011 06:08 AM
Giantmcm Does anyone know if Boosted is still doing manifold porting for the 2zz?

Thanks.
06-08-2011 01:19 PM
ekological Curious as to what tools you used. A simple die grinder? What bits?

TIA,
Chester
04-20-2011 06:35 PM
Eyelise Here it is after porting. Once again I was surprised how much I opened up the ports.
04-19-2011 04:03 PM
Eyelise I did this myself and I do think it is worth it if you are not going with a aftermarket header. I took off quite a bit of material from the header as there appeared to be a ton of mismatch by the carbon deposits around the header ports.

I'm now planning to remove material from the bottom of the header as recommended by another LotusTalk member.

I think it is all the more important for FI applications
03-25-2011 09:38 AM
ekological Does anyone know if Dave is still offering this service? I sent him a PM but haven't heard anything back. I was thinking about having this done along with my BWR Rev 310 install. Thoughts?
12-01-2009 09:56 AM
pyro40t How much are the ported and Ceramic Stock Headers?
12-01-2009 08:28 AM
glb Boosted, you've done a great job with the stock header, and I'm about ready to order.

But, much of thread is NLA and I was wondering about NA hp/tq gain on my elise w/PES chip.

Pls advs.

And, your PMs are full.

thx
11-30-2009 05:47 PM
Lotusmotion I have been following this thread with great interest because of the potential to easily and relatively inexpensively pick up a few extra horses by porting the stock exhaust manifold to allow the engine to exhale more efficiently.

When I was shopping around for an aftermarket exhaust in 2007, it was (and remains, I believe) a widely held position as acknowledged by exhaust vendors - and reportedly supported by dyno information - that the ECU will unlearn any hp gains derived from a freer flowing aftermarket exhaust, such as a Larini, Borla, BOE, etc. (excludes decat, sports cat, or headers). The gains from an aftermarket exhaust are lighter weight, and noise...not hp.

That being the case, why would any gain from porting the OEM exhaust manifold not be unlearned by the ECU while the hp gain from an aftermarket exhaust would be unlearned by the ECU?
02-24-2009 10:06 AM
Boosted2.0
Quote:
Originally Posted by Pestodude View Post
Would we need to tune for the header AND head porting though?
You wouldn't have to, but you would get way more power with a tune if you did header and head.


Quote:
Originally Posted by Bane View Post
I saw the same thing after 1700 miles of street driving on my car w/ the PPE header (over a month).

It takes awhile for the computer to stabilize but it doesn't seem to negatively affect the NA Lotus cars.

People have logged problems with supercharged cars after altering the header. I've seen up to a 10 hp loss after changing it without any tuning. Anything that affects the VE on a Lotus has the potential to mess up it's tune. Luckily CharlieX (Temporary goth.am webstore - excuse our dust!), PES, or Vision Function can correct that for you.
Not the ported stock header - it made over 10 HP on supercharged cars whithout a tune that NEVER got corrected back out. The reason is I'm not monkeying with the overall design, primary lengths, 4-2-1 or anything like that - I'm ballancing the flow between cylinders and eliminating unnecessary restrictions. Obviously the potential for greater gains exists with a properly designed race header, but apparently that sort of thing takes the stock ECU out of its "Happy place". Using the stock header, but eliminating the production defects that cause inconsistent flow between cylinders does no such thing.

Quote:
Originally Posted by vyuen View Post
Even for the supercharged cars?
Yes, even for supercharged cars.

Quote:
Originally Posted by Rugbyduck View Post
I think I'm going on 2 years now with my ported and ceramic coated header. Thanks 2.0!
No problem and glad to hear it!

Quote:
Originally Posted by choi0706 View Post
yeah, they're great.. I use them on supercharger installs.. great combination with the bronze ceramic coating..
Speaking of which - we had to go to CT for a while to see my Grandmother (she had a stroke) - I'll get to that headert this week.
02-18-2009 08:45 PM
choi0706
Quote:
Originally Posted by vyuen View Post
Even for the supercharged cars?
yeah, they're great.. I use them on supercharger installs.. great combination with the bronze ceramic coating..
02-18-2009 04:40 PM
Rugbyduck I think I'm going on 2 years now with my ported and ceramic coated header. Thanks 2.0!
02-18-2009 03:55 PM
vyuen
Quote:
Originally Posted by Boosted2.0 View Post
Nope - we did over a week of driving on Jay's car before he went back to the dyno. Plus now they have been on tons of cars for a year or two.
Even for the supercharged cars?
02-18-2009 12:27 PM
Bane
Quote:
Originally Posted by Boosted2.0 View Post
Nope - we did over a week of driving on Jay's car before he went back to the dyno. Plus now they have been on tons of cars for a year or two.
I saw the same thing after 1700 miles of street driving on my car w/ the PPE header (over a month).

It takes awhile for the computer to stabilize but it doesn't seem to negatively affect the NA Lotus cars.

People have logged problems with supercharged cars after altering the header. I've seen up to a 10 hp loss after changing it without any tuning. Anything that affects the VE on a Lotus has the potential to mess up it's tune. Luckily CharlieX (Temporary goth.am webstore - excuse our dust!), PES, or Vision Function can correct that for you.
02-18-2009 08:18 AM
Illumiloti
Quote:
Originally Posted by Boosted2.0 View Post
Nope - we did over a week of driving on Jay's car before he went back to the dyno. Plus now they have been on tons of cars for a year or two.
Would we need to tune for the header AND head porting though?
02-17-2009 08:27 PM
Boosted2.0
Quote:
Originally Posted by vyuen View Post
Does the Lotus ECU adjust for the differences with the port and polished header and negate the gains?

Nope - we did over a week of driving on Jay's car before he went back to the dyno. Plus now they have been on tons of cars for a year or two.
02-17-2009 06:20 PM
vyuen Does the Lotus ECU adjust for the differences with the port and polished header and negate the gains?
05-26-2008 09:20 PM
Boosted2.0
Quote:
Originally Posted by E.D. View Post
What's the $1K head porting and $2K head porting? In this service you also, besides the header, port some additional engine and other parts to further optimize air flow?

I'm not sure if you are asking what head porting is or what the difference is between the two so I will try to answer both.

By head porting I mean porting and polishing the cylinder head. This is done to improve airflow and airspeed through the cylinder head which will by default increase power. (Engines are big air pumps - more flow = more power). These gains are more noteworthy on engines that have already removed obvious restrictions from the intake and exhaust side of things.

The street version of the head porting means porting the cylinder head alone. (not header or intake manifold) It involves eliminating all castings and machining flaws and then polishing the intake and exhaust runners. I also do flowbench testing in addition to mechanical measurement of the ports to ensure that my target flow volume and airspeed are achieved as well as balanced. This allows me to ensure that the finished product will definitely perform.

The competition version takes things a step further. It involves polishing the combustion chamber to remove potential detonation sources, re-shaping the intake and exhaust runners significantly to maximize flow, and portmatching intake and exhaust manifolds to ensure that the gains made in the head translate to the whole motor. There is also some reshaping of the exhaust ports on the header. (I will include complete header porting services with this if you intent to retain the stock header) I will also include a valve job if you wish to switch to the higher flow MWR valves (recommended) and I will also install said valves & springs. I will also set valve clearance if desired. You will of course need to send the rockers, cams and lash caps for me to do this. New Valves and springs and new valve stem seals are NOT included in the price.

Here are the results of the competition port in terms of flow:

Intake:






Exhaust

05-26-2008 07:45 PM
E.D.
Quote:
Originally Posted by Boosted2.0 View Post
I finally have the porting business back up and running. The flowbench is long since done and I'm now offering cylinder head porting as well.

The porting cost for the stock header has increased $5 from $150 to $155 due to an increase in the cost ofmy abrasive media.

Head porting is $1000 for street port & polish with after flow numbers only and $2000 for competition which also requires that I have intake and exhaust manifold for port matching and exhaust flange shape correction. Competition also includes before and after flownumbers, combustion chamber polish, valve job, resurface head, and setting valve clearance if desired. If you have a stock header it gets the full port job and not just the port matching.

I highly reccomend use of a NON air injection head (00-early 03 Celica or 03 Matrix XRS / Vibe GT) as a starting point if you go for P&P due to an inherent flow advantage on the exhaust ports.
What's the $1K head porting and $2K head porting? In this service you also, besides the header, port some additional engine and other parts to further optimize air flow?
05-26-2008 05:48 PM
Boosted2.0
Quote:
Originally Posted by knucklehead View Post
Welcome back
Thanks! Our second daughter is almost one now (hard to believe) so mom has things well in hand in the house and I get to spend some quality time with my garage again
05-26-2008 10:09 AM
knucklehead Welcome back
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