Extrude Hone AFM Porting of a 1993 Mustang Cobra Intake Manifold
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- เผยแพร่เมื่อ 11 ก.ย. 2024
- I stopped by Extrude Hone to take a look at their AFM porting process and to get my 1993 Mustang Cobra / GT40 intake manifold ported.
Extrude Hone created a process called Abrasive Flow Machining, or AFM. A hydraulic machine pushes the AFM "putty" through metal parts, such a cylinder heads or intake manifolds, which ports and polishes the inside. The process is great for porting an intake manifold that would otherwise have to be cut in half and ported by hand since you can't normally reach all the way through the runners. The blue putty is in raw form. The light grey ball is the putty with some silicon carbide mixed in. The silicone carbide is the abrasive material that cuts through the metal part. The last blob is the putty that's been pushed through an intake manifold and contains the metal that was shaved off. It can be recycled and used many times.
In this short video, you'll see the Extrude Hone process on a four runner manifold and then a Mustang Cobra manifold. Each cycle of pushing the AFM putty through the manifold takes about 15 seconds and then it takes about 280 cycles to port the Cobra intake. As you will see at the end of the video, the manifold flows around 100 more cfm per runner, which is a huge increase. More importantly, all 8 runners are flow matched now. Runners 1 and 5 flow poorly from the factory, but it's all fixed now.
You can follow the build of this 1993 Mustang Cobra at / motorator
I thought the thumbnail was a crazy exhaust header.
Same.. i thought it was an monster "mustang" engin.
I thought the same🤣🤣
I was hoping it was😂
I thought it was clickbaut and i read it wrong
😂😂😂
So this is like playdough metallic sandpaper. Pretty cool.
Why do I need to take a shit after watching this ?
Emtildeath6666 haha same here. lol
Found this video while in process 😬👍
You're a Little Shit that's Why .
Did you just have taco bell
@@c431inf ditto
I heard about this years ago, very impressive. Just blew up my compressor porting the heads on my truck so I'm here procrastinating... I'd love to see them do an upper/lower intake bolted to heads, WITH headers bolted on. That would be the best port-match ever achieved😂
This isnt for porting. Its strictly for honing. They wpuld still need to be properly port matched first. But rhis is definately cool.
Enough internet for today
Yup thought the same damn thing LMFAO
Just getting started I don't know hope I'll end back here.
The pressure in my stomach is gone and oh boy what a feeling of relief after watching this video !....👍
Seems like a very slow and tedious process, I thought it would be a lot quicker for being a mechanized process. The results are very eyes pleasing if anything. I don't believe in those "before and after flow numbers", specially provided by them and being so balanced after the process.
Thanks for filming the process. Very interesting.
1:54 after thanksgiving dinner
Nothin' clog... never mind.
This comment will soon be the most liked one soon. Mark my words. Perfect.
Looking back this comment is accurate at the present time. I feel sorry for the guys at the water treament plant tomorrow
I called them years ago....they wanted over $600 to do a Stock 5.0 intake....It was Cheaper to buy a Victor EFI.....So if your building a sleeper with a Stock looking intake....it might be worth it...but for most people....Cheaper to buy Aftermarket....
600$ to take a shit in my intake! Wtf
A lot of people get this done to a new Victor intake.
@@kevinmasters7189 Because it takes 200 to 300 cycles to get that type of finish, frankie is corect it is MUCH cheaper to go after market, besides its under the hood, when some turd chaser wants to see under my hood it gonna cost you a run.
@@joshhanson6777
Expensive Intake....💲
@Rolando Mota it's that time of the month bro, let shim go
Stop traffic! We just went from 240 hp to 247hp
Lol, watch out
It would of been cheaper to just buy some NOS stickers
My buddy had his heads and intake done by extrude hone....it cost $1500....he flowed them before and after....Chevy SB castings....intake flowed 273cfm before...and 278cfm after....The Ports had almost a chrome finish....The car ran like Shit....would not idle..We wound up pulling the intake manifold back off the engine and glass beading the plenum and runners... it idled much better....Chrome Finish isnt good for a Carbureted type Intake manifold...but fuel injection runs better...because atomization is done at the injector.....
@@frankieford7668 Yeah I would agree. This smooth finish takes away the tumble effect of the intake charge. It would work best for a boosted engine in my opinion...
This isn't something you do on a stock motor to suddenly make 200 extra horsepower. This is a specialty process for high end motors (or at least those are the motors that really benefit from it). As for the guys saying the smooth finish isn't the best, you're talking street motors. They've adjusted the thought process over the years, the smooth finish is good for air velocity, they smooth em out now.
This has been around since the 50's, still the best method.
I read about this YEARS ago and thought it was a great idea and low and behold a video of this in action. BAD ASS .
Who knew you could make sausages with a cobra intake
I don't fancy "passing" sausages with silicon carbide in 'em... ouch !! 😯😯😯😯
On the other hand you'll never be constipated again once you've been honed.. 😅😅😅😅
@@peterfitzpatrick7032 or be able to stop that flow! Adult diapers here we come!
Finally a practical use for 5.0 parts!
@@royb5014 Hey! My 5.0 burns oil nicely thank you very much!
+Dan Manthe lol! keeps the mosquitoes away.
BTW, this is the process that Ford had done (from the factory: OEM) on the intake manifold/runners on the old Contour SVT 2.5 liter V6.
It put out (a respectable, considering the year) 200 hp.
I had focus with svt contour v6 with a cosworth head with bolt ons and made around 300hp
For whatever reason I always liked those SVT Contours. Couldn't hold back the vomit coming from seeing an SVT Taurus though
I remember the Taurus SHO!
A friend had a set of SBC World iron heads flowing 330 on the intakes in the mid 1990's from porting and then extrude honing. There was a guy here in S.Fla that did a lot of mustang intakes back in the day.
That is a fascinating process, thanks for sharing!
Congratulations on that .0005 you just received on your et slip
Very cool, not only impressed by the drastic increase in flow, but the runner balancing was fantastic. I suppose the pressure wants to balance out across all orifices.
if kinda crazy how much production cars are leaving on the table with their as-cast parts.
@@krusher74 costs too much, or rather I should say, it would eat into their profits too much.
I've *read* about this process in a mustang mag in the 90s, it sounded weird and I took their word for it. First time I've seen it done just now. Apparently it works best for boosted engines.
"best for boosted engines." how does that work?
@@krusher74 The magazine's explanation was with NA the rough surface inside the intake helps atomize the fuel (turbulence), smooth will make the fuel "stick" to the walls of the runners.
Boosted, the fuel goes through no matter what. That was the theory back then, newer tech and research could say otherwise
Really, If you can afford it, this is the best way to port heads or anything else that flows gases. The abrasive media flows the same way the gasses would, and the areas with the most restriction get the most smoothing automatically, giving the highest flow rate.😮😮😮
Wow that is so cool never new there was a process like that back in the early 90s i worked for a machine shop in Cincinnati learned as much as i could so after hours i could work on my 5mge engine did my own porting polishing balancing flywheel stuf like that did bore and hone a couple blocks here and there and i loved doing the work but the owner was a real jerk i would work on my stuff on lunch and after hours i was off the clock (they were slow told me to clock out my supervisor did) using the shot ping machine on a iron block and glass beading the head and the owner went off on me when he found out i was doing my own engine (we were allowed off the clock to use the machines as long as it didn't interfere with his pocket book) he bitched me out for doing my own stuff on the clock i asked him if he had bothered to look at my time card he said i hadnt clicked out my supervisor did stick up for me and told him i did he watched me clock out then the ass loked at the time card never got i apologize nothing stuff like that got old once i was done with what i couldn't afford to send off to paceo racing i got a new job they had a large employee turn rate because he treaded employees like crap i barly lasted as long as i did i got butched out for stuff that was done before me a flywheel grind that the guy before me had screwed up was my fault just because it sat around for a year i had only been there a month and at that time never even dine a flywheel grind that ass was so hard to deal with he lost a lot of lonng term race conrracts pretty sure they wrnt out of business after i quit a year or so later a couple of the machinist quit and started there own shop by then i had gotten into construction somthing i liked as much. Thank you for the link and great videos really like you guys!!!!!!
I had no idea - that process is ingenious, really.
Come on guys. You had me until the end with that hard-to-believe flow test. So not only did the honing provide a 50% increase over stock, with the stock part, but also flow balanced all eight runners? Jesus, can anybody in this industry be honest and stop playing dumb?! What flowrate was this test at? Perhaps one that no real world 5.0 will ever see? Or the exact one that exactly balances the ports? Is it that hard to include the flowrate on the nice graph? Why is the flowrate not provided? Easy enough to put it on there.
I see your point, but I wasn't trying to film an episode of Myth Busters. I just stopped by to pick up my manifold and shot some stuff that I thought was interesting on my iPhone. I'm sure Extrude Hone can provide you with more details. That being said, a nice feature they can provide is to balance the flow of the runners. Thanks for watching!
Matt D'Andria how much is this port?
They can do this on injectors and it helps a ton
9/11 isn't real
@@smokinjo79 decappping an injector and flowmatching/cleaning them is $75 and can triple output of a gm ls injector. This is $450 for a real world 10hp(actual numbers from guys who tried it)
Quality and equal runner's just over hour's worth of work. Great product takes out the elements of a unskilled labour with a grinder.
Freakin brilliant! I remember back in the day when I used to do this by hand.
Wow all the years I been porting heads I had NO IDEA this was a thing... So good.
1:55 The morning after eating at my favorite taqueria.
Reminds me of those snake fireworks. You'd light it and in 30 seconds you'd have a 2 foot long snake made of ash. I still remember the glorious smell.
More consistent than factory for sure. Very nice
I remember reading about Extrude Hone in a Hot Rod magazine years and years ago. Cool to see they’re still around.
Same. The article was called "Power Putty" the title was designed to make the "Y" in putty look like the putty material being piled up. The article showed various before & after photos. I remember that one. Early 90's I believe..
But. I doubt the effectiveness of it. You want some turbulence to the air-fuel stream to create a better mix. "Iron Duke" engines (G.M. 151 cid l4) even had special intake ports that swirled to provide additional turbulence. I get having more flow is less restriction, so having larger (slightly in this case) interior dimension of the runners would help increase the airflow rate, but that turbulence is lost on the mirror-polished surface, resulting in a less homogeneous AF mixture.
They even had a small ad in the classified section of Sport Compact Car as early as 1994.
@@Cammi_Rosalie I wondered about this. I would think the casting "grain" would actually help atomize the fuel more.
That is super interesting. Nice feature on the podcast Matt!
I like the video it has reminded me of a forgotten performance process
Similar to most people after eating Taco Bell... Seriously, this is brilliant and amazing process!! Has this been around long, cuz I’ve seen or heard of it? The efficiency and the before and after blows my mind! My mind is small but its still blown....🤯
You’ve probably got your answer by now, but it had became popular in the 80’s-90’s and featured in most of the magazines.
I can now clearly see what happens when I lay a long snake on the throne. Good visuals.
That's one way to polished your ports....awesome extruder..
Not bad...👍👍
That's awsome I would have never have thought this was a thing, very interesting
I have used extrude hone before great stuff takes the guess work out of PnP.Had some 3.0 heads and manifold done then had the exhaust side ceramic coated.
Glimpsing at the thumbnail I thought it was some insane crazy ass exhaust manifold for a split second
If the Reynolds number is high (it will be) then the flow will be turbulent, then the surface finish makes bugger all difference to flow rates.
thank you!
I bet that pumping machine has the smoothest ports you've ever seen.
Ive always been told this is how they do it but ive never seen it very cool
First time ever seeing this, thanks for posting it!
I was always warned about making the inside of the intake runners/intake manifold TOO smooth...
I was told that you WANT to have a little bit of a rough surface...so when the air hits the rough surface (which causes drag), it will cause the intake air to tumble & swirl, which follows on through into the cylinder head, and on into the combustion chamber, promoting good mixture of fuel and air.
I've also heard the term "laminar flow" used to describe the best type of smooth airflow inside of the intake manifold: Supposedly, the BEST airflow is not right up against the smooth, polished surface (i.e. like an intake manifold that's had! the Extrude Hone process done to it's insides) but instead, it's right ABOVE the smooth surface...
But, it STILL makes sense to me that you'd want the smoothest, lowest coefficient of drag possible when it comes to airflow: I mean, wouldn't you want the intake air to have the easiest possible path to the combustion chamber?
MyCatInABox I remember when this process 1st came out 25+years ago, and this very same concern was addressed. What you were told is correct for a carbureted/TBI application, as they employ "wet" intake systems. A smooth surface will reduce fuel atomization, something a carburetor is less efficient at by nature of design. It's a calibrated fuel leak. EFI Port injection systems are dry, the fuel is entering the air stream much closer to the valve, so the rough surface In the runner effecting air tumble/swirl for the fuel atomization has no consequence.
There are other things as play such as matching pressure impulses as the valves actuate. Air flow through an IC engine is an area of thermodynamics unto itself. But yes surface matters, how much varies on application. Something to think about is the gradient of flow... Edges vice center. Ideal laminar isn't possible, but a little turbulence at the edges can make the bulk flow smooth, and actually build pressure to ram air in slightly above atmospheric even in a naturally aspirated engine.
Agreed. You guys know what you are talking about .faulty method
Think about what you are saying and then look at the type of car this manifold comes from. It's port injected. The fuel isn't mixed in the runner to mix with the air. It's injected at the intake valve. Smooth runner is fine here.
No
Никогда не подумал бы что это делают именно так ))
I wanna see you do a Ford 6.0-6.4 diesel intake... It would be soooo satisfying to watch after I spent years presoaking for days in a hot tank, spray cabinet, sand blasting for hours, run through the ultrasonic and then spray cabinet again
I got here from a 'loose stools' video.....
.... & THIS is the scary stools video... 😅😅😅😅
Hahaahahahhahahhahaa holy shit literally I could only imagine googling loose stool and landing in this video. Spot on though, ya gotta admit.
...I got here from a 'scratchy skat' video.
I never realized that I've always wanted to know how they did that until now
Wow, impressive numbers
Like a giant version of the snake fireworks.
Genius. Absolutely genius.
I had this done in 1998 on a 350 crossfire intake, I think it was $400. I should have hand ported it first, it seemed like it just polished the runners.
I've been using extrude honing for years. Taco Bell and 45 minutes elapsed time and, bingo! Completely extrude honed from the inside out.
What a cool idea! A bit like watching your dog take a dump after eating a bag of charcoal but still, cool idea.
I watched this while taking a shit, thanks for the help!
I see some Tuned Port Injection (TPI) runners in there too lol. Going full on old school today folks! Love it lol.
That’s amazing. No idea this even existed, makes sense though
Lol, not buying those flow numbers since E honing has no real porting effect. Their own website claims this: 'Up to approximately 1 millimeter (Approximately .040”) is removed', so how did you get those flow rates again??? And that's calculated by the TOTAL width measurement, NOT material being removed from a single side. I know this because we measured my set of TFS heads that I had E honed in 1993. Turns out the process was ONLY good for cleaning up/polishing. If you got an extra 30 cfm with E honing, you did awesome.
What about physics and the path of least resistance? It's clear there are some benefits however it's my opinion that the process is a little to random to quote any consistent flow gain.
@@johnmorganwesternspy8786 This process has some flow benefits, but not anything like the numbers this video is trying to convey. Like I said, I've tried it and know of a very small handful of others that tried it, with little gains compared to the cost. We did it back in the days when this process was new and didn't have anything to benchmark it against. And with most manufactures now utilizing CNC machining, coupled with the vast availability of aftermarket heads and intakes, I have no idea why anyone would even go this route anymore.
@@231mac 60s muscle cars that want to make a "stock engine" run better. But that was late 90s. I thought only those crazy mopar folks did shit like this. Yes the trim (hemi I meant, that's the edit.) does. No it doesn't. Well watch this 20k stock hemi run.... see 11.50.
Someone did it to a 230 hp motor is what kills me😂
.040" sounds like a lot for this process to take off, you would never take anywhere near that much material off with standard honing and if you did it would take a long time.
That's amazing. I've never seen anything like that. I wonder how many passes at different grits it takes. Then when finished, how do you get the last bit out? I wish I could see a start to finish in person.
Very interesting. I had no idea they did this type of honing...
Pretty expensive for just pushing gritted putty through intake ports with hydraulics doing all the work... its not like its got 40+ man hours being ported by hand.
They have to build the tooling to mate to the machine.
It's a fairly slow process so that machine will be tied up for some time, plus all the tooling to mount the manifold had to be fabricated.
Bige4u but it works better than doing it by hand. Way more consistent. Gets all the surface
gotta buy the machine in the first place as well. sometimes these kinda places won't pay off the original costs to buy the machinery for years and years
Bige4u you are hired. Start your own and do it half price.
That's some abrasive shit right there.
Wow that’s a sweet setup looks awesome.
This is what happens to me when I have a burrito at Chipotles
No given RPM range in chart🤔 it might make it smoother for the air to pass but i highly doubt that putty is taking that much material away🤦🏾♂️ the gap i see between putty and intake when it is exiting, shows it's not enough pressure! FYI you would have to restrict the exit hole's to keep the pressure up with speed pushing from the back duh!🙄 my .02!
twotwocold ignorance detected . . . It's a proven process for over 25 years now
Name calling shows it's bullshit and I will never give a penny😭😭😭
@@cruzinezy1968 It's proven for polishing. It does that very well. I had a set of heads done back in '93 and they came back beautiful, but it was a total waste of money HP wise. Even their own website states this: 'Up to approximately 1 millimeter is removed'. Not only is that nothing when going for flow numbers, but the key phrase here is the 'up to' part, lol.
I depends on what they are using as a thickening agent. If it acts as a non-newtonian fluid then it could potentially be using a lot more pressure than you would expect. Shear-thickening fluids actually become more viscous as you try to push them through a pipe. None the less I call BS on the 50% flow rate increase from this process. I can't imagine how that would be even remotely possible.
@@cruzinezy1968 TROLL detected, if you got to resort to that type of non-adult behavior your a TROLL, sure it is a proven mechanism for "POLISHING" the internals and not much more. Cheaper to buy after market....
Awesome, thanks for showing this process. I would love to port my 93 Cobra's intake!
Super clean
@ 3:51 THEY RACKED A LINE UP TO THE RIGHT😂😂I LIKE THERE STYLE 👍🤘
Hello, what type of abrasive media did you use? A 0.2 micrometer surface finish is required. We would appreciate any help you could provide.
Lol what a waste of energy and money. Just run cold air intake (no filter) into a bucket of sand, then redline a few times. Works every time. You are welcome.
Are you sure that the result is the same?
@@samfischer7443 Can confirmed, gained 30whp
Sam Fischer yep, I like to use my chinchillas volcano dust after he’s done with it. Works wonders for my V6 rotary motor.
@@Eunos_FD3S I'm so fucking confused as to what's going on and if your serious.. 😂
@@Eunos_FD3S Oh snap you got one of those triple piston Doritos spinners?
It's an interesting idea, but how do you get it all out when it's done?
There is no way that is equally “ported”.
Its not, a friend had this done to his header and it was messed up. It took too much material out of one side to the point where they wouldn't seal anymore, and still charged him a shit ton for the job. I don't know maybe in some cases it might be alright? I like the idea but then you find out how much it costs. I would rather get a cnc job done, I guess once you start to cut stuff apart and welding it back together.
If you claim that this is not equally ported, how do you respond to the flow ratings (cfm) being nearly perfectly matched between each runner?
john L - you are correct it is not controllable. its possible that you could block off the best flowing ports and do a first pass on the ports that flowed poorly to begin with and then move onto doing all ports. you will also notice that the cutting paste is not touching the entire inside diameter at the exit point so little cutting action would be seen at that point. Liquid flows around bends on the outside radius and barely touches the inside radius. depending on the viscosity and the radius it is possible to drill a hole on the inside of a radius and create vacuum even though pressurised fluid is passing through the pipe.
John L...that’s why it’s not as popular as it was when first introduced.
It doesn’t take a rocket scientist to know that at any point between entry to exit that you are not getting even/equal surface removal - especially at the end.
@@ZEPRATGERNODT They can just push the paste from the other end to compensate
I like how everything gets the same amount of material removed.
This is smoothing and polishing and cleaning, not necessarily porting. Yes its taking some material so i guess it could technically be called a port job but i dont think thats its main, intended desired effect. It smooths out the runners and transitions very well.
They have course media that can remove a measurable amount.
It was real popular in the late 80s 90s for production heads, certain racing classes as a way of cheating
Hey my poop looks identical to this stuff! Time to see a good mechanic!!! 2:05 similiar to my personal flow!!
Good job I was already on the can while I watched this one🤣
I got an extruded and honed exhaust manifold after two chalupas and a cheesy gordita crunch from taco bell last Thursday after work.
EH has been around a long time...long runner, dual plane intakes even heads can pick up from this process. SOme do it after porting others it gives a similar effect.
All the key board scientists picking this apart are clueless. Many 5.0 and TPI intakes, heads back in teh day were done with this process, nothing else. You can specify how aggressive you wanna get.
the moment i realized what was going on.... fucking brilliant
saw this while on the throne, thanks for helping my bowel movement. This is the equivalent of hearing water dripping, but for shits.
What about where it's coming out of the ports an falling down, would that wear down the opening in an undesirable effect
Egg shape the holes....that was my thought...
It's not under as much pressure there, maybe?
@@silvermediastudio true , it would only be affected minutely I think buy just the weight and abrasiveness of the mixture at the time but still a little bit of honing somewhere you might not have wanted
Its not going to affect anything
The manifold is for a Ford 5.0. But the runners are off a GM TPI
I was told years ago that a carbureated engine will not run on the street because there is not enough turbulence to atomize the fuel/air mixture.
While improved flow rate through the intake is a good thing, the ultimate bottleneck is the obsolete poppet valves and eliminating the valves yields greater improvements in power.
you cant call poppets obsolete, what have they been replace with?
Congrats on your added 5-15 hp :P
Fascinating... I like this indeed
never imagined it looks like sausage being made. sooo interesting.......................................................................................................
Interesting technology
abrasive play dough for adults - sweeet !
Smokey Yunic was doing this to the heads on his Hudson back in the 50's . Anything to get around Bill France and his rules .
This gentlemen once told me the true purpose of the ring on the front of tuner cars was so a tow man can pull the car out of a ditch after the person had showed off for the first time.
I can't imagine making the air intake shiney does anything at all to total performance
That was interesting to watch.
Smokey Yunick did this with Beach sand from behind his shop back in the '70's
On Hudson 6 cylinders
That is really clever.....well done
WTF did I just watch!?! Thats how it's done??? I always thought extrude honing was a blasting process, wow!
Greif Inc Fiber drums! Good man!
That's brilliant 👍
Nobody told them a 5.3 ls makes more power without honing anything?
I haven't seen a GM TPI intake in years, but prob still cheaper for that guy to go get an LT4 style intake or Edelbrocks version. I looked into this for my 99 Cobra intake since there are zero aftermarket ones (basically) and it was money that could just go towards some cams, rear gears, etc. that will make a noticeable difference.
Never seen such a thing. Great finish on those runners, though that chart is a bit cheeky starting at 100 instead of 0!
+iOutwrite This process was used to increase the flow on the factory engines in the Ford Contour SVT. They did a one pass process on the heads and intake manifold, made 195hp. Later in the production of the car they moved to a two pass process that yielded 205hp.
iOutwrite It doesn't matter what number the chart starts at, it's showing a difference between the before and after. whether the chart starts at 0, 50, 100, 150... as long as it starts below the before number, it would not matter. just imagine the chart starting at 0, and folding the paper at the 100 mark. it doesn't change the graphs representation at all.