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Thread: How to Port the Stock Throttle Body - Step by Step w/ Pics!

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    How to Port the Stock Throttle Body - Step by Step w/ Pics!

    A lot of posts on porting the stock TB lately, so figured I'd finally formalize a how-to on it. Very simple mod, about 2 hours worth of work depending on how far in detail you want to go, and cheap easy way to get nearly the same gains as a 400+ dollar SBTB!

    Stock Un-Ported TB:
    Stock throttle body is very rough finish, and has a HUGE casting nub on the inlet side. Very easy to see its not the most high-flow friendly piece. Also the TB blades have blocked off edges, and the TB screws are WAY longer than needed to be.






    Tools Needed:
    Dremel will do 99% of the work! Pic is flipped, so right to left is the order you'll use the bits.
    1-2: Cone shaped & cylinder shaped grinding stones to make quick work of getting the casting nub ground down, & the cone one is great for knife edging the blades.
    3-4: Big & small sanding disc cylinders. great for smoothing out the rough surface material in the TB bores, & smoothing over the grinding stones work.
    5: Sanding flap disc. perfect for smoothing out the metal even more to a near shiny finish on everything from the bores, to the tb housing, to the blades, etc.
    6: Cotton buffing wheel. for those that go above and beyond, throw in a little compound, & can buff the sanded areas out nice and shiny.




    Blades:
    -The brass material the blades are cast from is a bit rough, can smooth them out so they are a bit slicker, get any imperfections out, and knife edge the sides. just be sure you do NOT decrease the diameter of the blades. doing so may cause idling issues with more air getting by when the throttle is shut.

    -Initial knife edging & smoothing with a grinding wheel.




    -Intermediate finishing with flap wheel.




    -Final polishing with compound & cotton wheel.


    Throttle Bores:
    -After grinding down the casting nub with the grinding bits, smooth out all the surface area with the sanding discs & flap wheel. on most TB's there's a small lip where the bores are cast through, can smooth out this transition so air flow in and out is a seamless flow.

    -Can see in the first pic the TB bore hole on the bottom left has a small lip around the perimeter. Can grind this flat so the transition is smooth & seamless as in pic 2.






    Screws:
    -The stock screws are extremely long. There's two options at this point. If you dont plan on disassembling anything again, can grind the screws down totally flush, JB weld the threads, can even JB welt the transition along the shaft so its more aero-friendly, and even grind the screw heads down. The other option that I took, for if for some reason I ever want to disassemble the TB again, I left about 1 thread left on the screws for a little extra insurance they dont come loose, lock-tite on the threads, then center punch the back side of the screws to lock them in place. the screws are hollowed out so they punch easily.




    -Also on the outlet I chamfered the edges a bit to smooth the airflow pattern out on each bore.


    Finishing Touches:
    -Final smoothing & polishing done. Didn't bother to go for a perfect mirror shine, but nice and smooth for air to flow over without creating turbulance.




    -Completed! Painted the outside for a full finished look with Duplicolor Anodized Paints. Also left the very outter lip on the intake elbow side with the textured finish for a little "bite" on the intake elbow to reduce any chances of it popping off compared to if it was smoothed out. Doesn't affect air flow, so just a small tip to help hold things together better.




    No go port your TB!
    Last edited by Harley#356; 06-22-2007 at 05:15 PM.

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    HarleyDangerous
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    Great step-by-step how-to. It seems fairly straight forward and would have to yield the same performance as a sbtb... Any difficulties re-installing or any adjusting issues?

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    NO

    your not touching/messing with the TB blade adjustment screw

    when you put it back on and put the tps back on,,,just need to set your TPS which is covered in the How to section also

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    HarleyDangerous
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    When polishing the two bores in the TB, how did you make sure you weren't taking out too much stock or making them out of round?

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    you dont mess with the area right where the TB blades seal to when closed....

    to the direct right and left of where the Tit was....if you get to much off two one side or the other...who cares ..the air has already been metered back at the maf....after it gets past the TB blades...it dumps into the plenum which is one big hole to the top of the SC....and then it gets chewed up again going through the SC>
    Last edited by bgstew6; 06-22-2007 at 06:27 PM.

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    yep meant to mention that. adjustment screw wasn't moved at all, and although you could port the TB with the blades in and center shaft in so you dont have to remove the TPS, and smooth out the front surface and get rid of the casting nub, its easy enough to reset and even from the factory should be checked and set to 0.99 so 2 more screws and the TPS & blades come out so its a bit easier to work with porting each piece separately.

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    Great, one more ****ing thing to do now when the trcuk gets back... thanks alot.. damn u josh!

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    haha, dont forget to port & polish & gasket match the plenum while ya got the dremel out

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    I highly suggest using a diegrinder on those peices....doing it with a dremel sucks azz lol

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    dremel with flexible 2' extension worked great here for the plenum
    no big casting nub area's like the TB so not a lot of material needs to be removed. flap wheel will do 90% of the work

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    Quote Originally Posted by Harley#356 View Post
    haha, dont forget to port & polish & gasket match the plenum while ya got the dremel out
    Thats why you're doing it for me.

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    youp same here....

    Lower intake manifold sucks major ***

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    Quote Originally Posted by Krix330cic(NJ) View Post
    Thats why you're doing it for me.
    lol i do have a spare bone stock 03 plenum in the basement......

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    remember... all the ICE CREAM.

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    lol ice cream is the LAST thing i want right now haha. so sick of this sugary chit! i want a friggin prime rib steak! extra rare!

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