My efforts on my T-body continue....

I found I had the PERFECT options in my garage for sanding that JB Weld. I tried my palm sander with 150 and 100 grit paper (all I had), it was doing it (but would have taken hours).

Thanks to Harbor Freight, I had this accessory that chucks into my power drill, and it has different "discs" for it (from sanding discs to scotch brite like pads). I used an "agressive" disc to get most the work done and smoothing it over with the scotchbrite disc.

I have some touch up on the JB Weld to do (some tiny air bubbles where I don't want air bubbles). I'm holding off on pics until I have the surface as I want it. Couple more days. But so far, so good!

 

OK, I changed my mind some. I finished sanding the JB Weld and decided, I will do a final "fill in the air bubbles" when I am done (if I already found a few, I will probably find a few more).

The only other thing I did was used an old gasket to determine how wide the "flare" will need to be. I still need to determine the depth I need to grind (and I have yet to bring myself to removing my T-Body to figure that out).... I will more then likely have to do that soon.

Anycase, some updated shots.

 

I had a friend that did what you are doing with this N/A bonnie and it was letting to much air in. He was mostly stock tho and didn't have a HP tuner to tune the car. I also put it on my car and scanned it and I was running lean with it on my car. I just wanted to give you a heads up on it...I don't want you chipping a piston or anything because you are running to lean.

 

Thanks for the input Chevy Commando. I admit I am outside my realm on this project, so as people provide me input, I'm all ears to listen and follow up on it.

I've been in touch with a guy who did this same operation on a Bonneville successfully (it's been on his Bonnie for a few years now). As I understand, the key element is to making this work is to also have the car tuned to handle it (which should prevent the lean condition you mentioned). So that is part of my master plan with this.

 

OK, this step I am not yet finished with. I began grinding the flares for the outlet on the Throttle Body (not yet done). I began last night but have not had a chance to finish. So far, so good!

 

Crazy amount of work you are doing.

Makes me glad I took the lazy way :P

 

For the time I'm screwing around with it, it would have probably been more worth while to buy the High Velocity one. To be honest, if I could just spend a day messing with it (instead of an hour here or an hour there), I'd be done by now.

But it's been a good relaxing project. I've never done anything like this and it's been great to play with the Dremel. I find the entire project a good relaxing break at the end of the days I get to work on it. If this works as I hope, it will be nice to say I put my hands all over this one from start to finish.

 

OK, no new pics yet... But the outlet flares look AWESOME. I am trying to polish the inside to be smooth. I am close to done with this phase. Next phase, I intend to paint the exterior of this (give it a sweet look). Recondition the spring and throttle linkage, re-assemble and show time. This mod will probably not go on the Monte until Spring time with a host of other mods.

Now, important safety notice. When grinding, WEAR safety glasses. I do wear prescription glasses (and my last pair were so big, they almost doubled as safety glasses). My current ones are not that forgiving (either way, doesn't matter, it's no excuse, wear the dang safety glasses).

Long story short, my eye wassore as heck, I spent 1.5 hours in the ER on my way into work and there was a piece of this project in my upper eye lid. My vision is fine and everything will recover just fine (the eye is still a little sore).

Chibi - You win.... Tacking in my ER visit co-pay to MY project, I shoulda just bought the out-of-box mod. But this ER visit was avoidable and my own fault. I'm still pleased so far with my progress and I think it will will all work out (I really couldhave done with out the ER trip).

Again, if you learn NOTHING else from this thread WEAR SAFETY GLASSES....

Good grief, I now feel like this mis-hap is comparable to the men vs women oil change Internet joke/e-mail....

 

I just wanted to give everyone some updated pics. I believe I might finally be done on the grinding part of this project.

I have to get some additional bits for my Dremel, as I want to give the T-body a polished look/feel on the inside (as it stands, I was using a "polishing stone" on my Dremel and it's not giving the desired results, and I have not touched the throat of this yet, as I don't want to make any significant changes in it's diameter as a result of my trial/error in finding the right method to polish this).

My MAF sensor now fits like a glove on this and once I get the inside polished, I hope to paint the exterior and recondition the throttle linkage and spring assembly (and re-paint those).

 

POLISHED!!! Had to acquire some new Dremel bits (the abrasive buffing bits). I think at this point, the inside of this T-body I believe is completed!

I now have to remove two screws who's heads broke during dis-assembly. And then clean up the exterior to prep for paint.... I think this T-Body will look sharp when done (and hopefully yield some worth while results with everything else I have planned).