Tuesday, February 16, 2010

More on Smallport Manifold Cut-n-Shut

Most of the pics below belong to my dear friend Dereck. He's done doing cut-n-shut on his 4A-GE smallport intake and you can see the result on the pics below. Smallport intake manifold faces the wrong side when the engine is put longitudinally in RWD. On Charmant (and many more example from other model, i am sure) the throttle body will hit the clutch master cylinder and unless you want to go Fred Flintstone on your car, you need that throttle body.

Here's the problem i mentioned.

Here's what cut-n-shut basically is, taken from my older post.

Here are shots of Dereck's finished manifold taken from his blog. First is the back side..
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and here's the front side..
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I sent Dereck's pics to my workshop mechanic thru MMS and immediately i got this reply pic.
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Looks like they are almost finish with my manifold also! Only i see that they are doing it the slightly harder way. You can see that they kept the bolt threads on the back side just so that they can simply bolt in an aluminum plate to cover the old TB hole. That's easier than cutting and shutting the back side for sure. But as for the front side, it's a lot harder this way. You can see that they put an aluminum block there so that they can redrill the TB bolt threads. Ah well, that's how they prefer to do it.. It's not really my concern as long as it functions properly.

Dereck warned me that i need to make sure the cable gas bracket is also moved to the correct side. That's one thing to pay attention to on doing this work. Anything else you care to share with us, Dereck?

***update 18-Feb-10***
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4 comments:

  1. I would like to say in envy that your "cut n shut" is the best i have seen, the throttle plate that they made looks like it has the same angle as the RWD manifold... which i have.. lol, well, whats done is done with the cutting, the hole that leads to the cam cover breather is made obsolete after the "cut n shut" method and an oil catch can should be used if you wanna keep the engine bay free of residual oil lol, im not sure as to why the cover breather leads to the intake..... i am not a mechanic or anything like that but i have a competent mind to technical things so i would guess its for some sort of lubrication purpose for the throttle or what ever else, another advantage that i have been forever pondering on with this method is the airflow, my original plans were to order a reducer plate for the "Bigport" intake to work on the "Smallport" AE92 head, such plate could be made but i am particular about such things that are made and not tested. Either way, the "cut n shut" method can save you alot of money, and the intake manifold in my opinion is noticably lighter than the RWD version, will update my blog with the new pictures i took and the new ones im taking amidst the cleaning going on at home lol.

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  2. ....*waiting anxiously*

    Edgar, is it done yet? is it done yet?is it done yet?is it done yet?is it done yet?is it done yet?is it done yet?is it done yet?is it done yet?is it done yet?

    LOL!

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  3. lol@stanley.. patience is a virtue of a real drifter bro. project-wise, it's far from done. i still have to swap a corona diff to fit AE86 LSD and not to mention interior upgrades but as far as the engine swap goes, i am figuring it's about 70%. still a lot to do i reckon. fuel pump installation, A/C and P/S brackets, EFI wiring, exhaust.. give it 1-2 months and the engine should be done.

    yeah dereck, the TB will be mounted at an angle as you can see on the update pic. looks like a job well done (and money well spent ^^)

    i'll just reroute the oil vent hose to the air filter pipe. maybe i'll use a fuel filter as oil catch can as i think US$30-50 for one is ridiculous.

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  4. old method here is to use a Gatorade bottle lol, far cheaper

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