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TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old January 10th, 2012, 18:53   #16
Ben Dur
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^^
getting thin on the intake manifold are we?
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Old January 10th, 2012, 19:29   #17
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I'm watching this thread
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Old January 13th, 2012, 20:48   #18
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no photos?
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Old January 14th, 2012, 02:03   #19
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I have some on my pages.. not showing much, but you might find something there.
http://npsheads.com/index.php/cylinder-heads/diesel
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Old January 14th, 2012, 16:01   #20
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Most of the pictures I've seen either show now useful parts of the modified port or show the ports with no noticeable work done. For the average person porting I would say a polish job on the intake and the exhaust is pretty straight forward. The most noticeable difference I saw was the combination if valve shape/back angles and the valve seat profile.
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Old May 8th, 2012, 19:27   #21
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Hopefully I'll receive my AHU head soon so I can start porting. Lots of what I can see in some of the pictures is clean up work, not much for increasing the size of the ports. What about the bowl area on the intake and exhaust ports? Just clean up and smooth inside of there?

How close is it to the ALH head Matt showed chopped up to what an AHU head will be?
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Old June 1st, 2012, 08:15   #22
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I'll be taking some pictures to get better comparisons, but take a look at these two intake bowls from FUB and GTITDI
FUB pic, unported

GTiTDi ported

Looks like a little of the bump near the valve guide is removed. How much of this can be opened up and still maintain swirl? Other than smoothing of the intake bowl and port, what else can be done here?

How much of the red here actually get removed on the exhaust port?
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Old June 1st, 2012, 20:33   #23
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Not a whole lot input, all secrets to porting? Here is the spot I am proposing to open up.


The port on GTiTDi's head appears to have this part removed.
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Old June 2nd, 2012, 06:59   #24
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Jon - Can you post a picture of the intake port at a different angle - maybe a little more from the side? - something in the picture does not look right (Like there's a huge ledge in red compared to the intake port to the right).

The intake port on the right (not red) looks quite a bit different than my ALH intake ports. I defer back to Alex22's work where there were "significant" reductions in swirl with any major changes in porting at useable valve lifts (under 0.400"). The most gains were had with valve seat angles and back cutting the valves per Alex. This is also on an AHU head so comparisons may not be 100% accurate.

Regarding the exhaust port - I outlined in Green more/less what I did.



There was quite a bit of "hourglass" shape right above the exhaust seat which I removed completely so the port is the seat ID all the way up to the ceiling. This was on the sides of the port as well as the outside radius as well so it's a lot of material to remove all the way along the port. I kept the valley's on either side of the guide, just made them deeper and wider and blended them into the wider walls. The outside radius is probably a little sharper than I drew in the picture - Follow the outside of the green line in the vertical areas and the inside of the green line in the horizontal areas. To match the port on the exhaust gasket the "floor" on the short side radius was lowered. In hindsight, maybe I would have left short side radius alone (where the red stops in the picture) and tapered the floor out to the gasket dimension. Basically connect the end of your red line to the end of my green line. The crossection was enlarged significantly on the outside radius so there was probably little benefit (and probably some detriment) to taking as much out of the short side as I did.

This is all just my intuition - I have no data to back this up. For all I know I reduced flow in the exhaust port.
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Old June 2nd, 2012, 07:33   #25
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Here's some pictures of what I was trying to describe above on the exhaust ports

Unported


Ported


Unported


Ported - this is not complete, but 80% of the way there - there was more material removed from the sides deep in the port. For some reason I didn't get pictures when I was done
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Old June 2nd, 2012, 08:07   #26
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Thanks for the pics and info! Its very difficult to get a picture of it but so easy to see with the naked eye.
I colored red, around the corner to depth of what I'm proposing removing.

Its like the port is round, like GTiTDi's pic, up until the part in red, it bumps out from the side into the bowl. I will try to get better pictures. I wish I had completed the CMM training at work, I'd model it 3d
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Old June 2nd, 2012, 08:50   #27
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After staring at it for a while I think I "see" it. That's one of those areas where removing material might help or hurt.

If it helps balance the flow around the valve by providing restriction in that area (compared to the short side where the air just skips over), removing it might hurt overall mass airflow at certian lifts because all the air tries to go to one side of the valve instead of all the way around.

If it's just a swirl inducing feature, than removing it might improve overall mass airflow but at the sacrifice of swirl/tumble.

As you can see, I'm not a fan of messing with the intake ports unless you know what's going on. For some reason I don't think the exhaust port is as sensitive and didn't have any problem modifying it with no supporting data. I don't know why.
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Old July 2nd, 2012, 06:54   #28
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I did a little work on the head last night. I removed the bump I outlined above, here is a better representation of what I did(pic stolen from Whitbread)

Blended the red area into the green and cut it back a hair to make it straight shown in blue, just not that extreme.

FUB, I see what you did with the exhaust port now, I should be able to get started on that soon.
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Old September 10th, 2012, 09:05   #29
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Done







Valve job done with big help from a forum member, thanks!
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Old September 10th, 2012, 11:52   #30
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what tools did you use?
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