Introducing Stage 2 Intake Porting

[JJFormato]

Stage 2 LS2, LS3/L76, LS7 intake porting While the intake manifold is more often than not a restriction in the induction we aim to make it as little of a restriction as possible. All of our typical stg 1 LS2/3/7 manifolds are ported to about 93mm, or 3mm larger than the stk TB flange opening. Our ported FASTs are closer to 95mm but they are over 94mm. This is all in the interest of most gross flow at the entry and most plenum volume. Typical stage one manifold porting is very extensive and time consuming to port correctly. We remove a very substantial amount of material from the plenum, TB flange, and runners. We offer the most aggressive porting for the dollar and strive to go the extra mile in all that we do: porting, tuning, and installs. We avg over 11rwhp and 13rwtq from our base Ls2 manifold porting with over 420 LS2s to our credit, 95+ LS7 (18RWHP and 20RWTQ), 60+ LS3 & L76s (12RWHP and 15RWTQ) and over 400 TB's.. We were curious as to how far we could take the manifold by really opening it up to the next level and taking a page out of the FAST/Wilson notebook... Stage 2 porting is taking the manifold to its limit - as much of the plenum is removed while still staying safe from vacuum leaks, which takes about twice the time to port. The FAST manifold utilizes as much plenum volume as possible within the space requirements - the larger the air reservoir the less likely it is to deplete it at medium and high rpm. Hence the difference from an LS1 to an LS6 manifold, plenum volume. (We have tested this manifold swap many times for an avg gain of 10RWHP and 10RWTQ; again plenum volume.) We rework all the runners for an even deeper cut and we use a much more aggressive sanding method, even deeper than the 8 inches we typically port in the stg 1 manifolds. For stage two manifolds we remove the inner posts and completely flatten the plenum floor all the way to the back on the inside of the manifold as well as the outside so as to make a sort of air gap between the valley and manifold base. We epoxy small aluminum plates, screw them in, and then epoxy the inside as well, to prevent any air leaks. This stage 2 manifold porting is a cheaper alternative to a FAST manifold, but it is also designed for someone that is trying to FULLY optimize their power on a budget. We are targeting those that want the MOST from the stock manifold at a decent price. On our own GTO we tested the stage 2 manifold vs our stage one and we picked up an additional 6rwhp and 7 rwtq on an A-B test on the dyno same day, same weather, same engine conditions. This is in addition to the 11/13 from the stage one manifold We also had an independent test done by a shop in NY and they gained over 15+rwhp and 18+rwTQ. We do not offer stg2 for the FASTs. We port all of them as aggressively as possible over 3.5 hrs per manifold. Stock opening: Stage 2 opening: Stock floor: Stage 2 floor Stock Floor: Stage 2 floor: Stage 2 on the top, stocker on the bottom: Stock: Stage 2 The Stage 2 manifold pictured here has been on our GTO for the last year with out any problems what so ever. It is after this long term testing and dyno proven results that we are proud to now offer this power making manifold. This is for LS2, LS3 and LS7 manifolds. We do not port the LS1 & LS6 manifolds, as there are not any measurable gains from porting these. These are pictures of the just finished LS7: Throttle opening Throttle opening Floor Intake runner Intake runner The Stage 2 intake manifold is $375.00 and if you want to add a ported throttle body, that is $100.00 (save $50.00 off TB by ordering together), plus shipping (usually no more than $20.00). The core charge for both is $550.00 ($275.00 each), it is refunded when we receive your undamaged intake and TB back. If you elect to ship us your intake and throttle body, the turn around time is typically 2-3 business days. Our shipping address is: Fasterproms 19103 Sunlake Blvd. Lutz, FL 33558 To order call 813 476 7364. Thank you Dan Fasterproms

[JJFormato]

Corvette Intake Removal
Tools needed:
3/8” Ratchet or speed wrench and ¼” ratchet
8mm short well,(8mm swivel recommended)
10mm socket deep well
Medium flathead screwdriver
Medium needle nose pliers
Brake cleaner solvent
Rag/ towels
*Tips- Some connectors have light grey slip locks in them (TB, MAF, some injectors) squeeze the sides of the lock and slide it off and then you will be able to pinch the connector to remove it.
-Towels work well as fender covers
Instructions
1) Disconnect and remove the Air intake system and MAF.
2) Disconnect the following electrical connectors: throttle body, MAP sensor(3 wire connector attached to the int manifold behind the TB flange), Evap 2 wire blk (solenoid is mounted on Passenger head) , (The injector wire harness loom is held up by 2 plastic tabs on each side of the fuel rail. These can be removed by a flat blade screwdriver, and pushed back in when you are reinstalling.) Injectors, pinch the end clip and pull. The hard black plastic line is the EVAP. To remove push in the little white ring tab on one side and pull out, give her a slight wiggle and be patient . Remove both lines from the solenoid on the passenger side that crosses over to the driver side of the manifold just behind the TB flange. (Z06s Disconnect PCV line to the passenger side valve cover, it is the same style connector as the one just before the TB on the induction tract) Disconnect the rubber u molded PCV hose on the passenger side of the manifold that connects to the valley cover under the manifold just behind the TB flange.
3) Corvettes require one to loosen the back 4 rear intake bolts with black brackets before you remove all the 4 10mm Fuel rail Studs. Pop the 2 gray plastic supports that hold the thick black corrugated covered wire to the alternator on the driver side studs with a flat blade screwdriver. The back 2 int. man. bolts will not come out until all bolts are removed and the manifold is pulled out. (There is a grounding strap holding down the front driver corner of the rail it is an 8mm intake bolt). (Z06s must lift up the nameplate and swivel toward center of manifold to gain access to the passenger side rear fuel rail stud.) Pry the rail up from the outside using the flat portion of the manifold as a leverage point. This should pop the injectors up out of the manifold. You will have to do this on both sides of the manifold. With the fuel line still attached to the fuel rail, lay it on a towel upside down on driver side of window. Pull the thick Black wire with the gray mounts on it out of the way.
4) Remove the front 8 8mm intake bolts, this will allow the intake to be lifted and pulled forward to remove the back 2 bolts and brake booster line in the rear of the manifold (Z06s remove the vacuum hose). (If you are doing this alone, tape to hold up the back 2 bolts keeps them from catching on the heads.) from the driver side pull out the manifold disconnect the small 3 wire connector for the oil pressure sensor and pull the brake booster line over to gain more working room. OR remove the brake booster line from the booster and feed it back behind the manifold. Once the back 2 bolts have cleared the cowl pull them out. Use the pliers to slide the clip holding the brake booster vacuum line.
5) With the manifold off and the cylinder head intake runners exposed you will find oil in the ports. Any oil consumed lowers octane rating and thus increases the likeliness of spark knock. I use a rag sprayed with brake clean to remove as much oil as possible. Wipe clean all the tips of the injectors and the o rings.
I hope that this helps. It is much easier with it all in front of you. Ultimately, you are responsible for what you do to your car. I have never hurt or damaged any car using this procedure. If you are inexperienced get a qualified mechanic.

[Sébast19X]

Wow pretty good job. I'm interested to see a dyno graph comparaison between a completly bolt-on car like mine (stock cam) of course with stage one intake vs stage 2 intake porting. This is alot of R&D .

Good job , I'm interested in stage 2 , I need to squeeze all the LS7 stock intake potential.

Thank you,
Sébastien

[JJFormato]

Originally Posted by Sébast19X

Wow pretty good job. I'm interested to see a dyno graph comparaison between a completly bolt-on car like mine (stock cam) of course with stage one intake vs stage 2 intake porting. This is alot of R&D .

Good job , I'm interested in stage 2 , I need to squeeze all the LS7 stock intake potential.

Thank you,
Sébastien

Thanks Sebastien, we are working on that, and will be posting them as soon as we can.

[22053927]

Got a few AUSSIE OAK trees need porting, any ideas?

Ron.

[JJFormato]

Originally Posted by 22053927

Got a few AUSSIE OAK trees need porting, any ideas?

Ron.

Hey Ron, when are you coming back?

Dan

[kbobk]

dyno results before and after on the LS3 stage II and ported TB are listed for my car here

Car is a 08, LS3, MZ6, 3:90, LT's, Catted X, B&B Rt66, 60lb injectors, Vararam, Whiplash cam, 25% UD pulley.

They posted the before dyno up tonight. Should post the after dyno up tomorrow afternoon.

[JJFormato]

Here is a good link for those doing there own tuning, or having others do it:

http://forums.corvetteforum.com/c5-s...s-and-tbs.html

[JJFormato]

Another Stage 2 LS7 is on it's way to my hometown of Flint Michigan.

[JJFormato]

Now have a LS7 dyno to show the gains from a stage 1 to a stage 2;

This Car is an 07 Z06 with the following mods:
Callaway CAI, Fasterproms Ported TB and stg 1 manifold, STOCK EXH manifolds, B&B Fusion catback, Fasterproms custom tune.
Run 1 was a baseline pull with all aforementioned mods, fully optimized.
Run 6 was Stg 2 manifold and a tuning tweak, more fuel.

We were pleased to get this kind of power in weather in 90F + air temps.

Jeremy Formato

[Sébast19X]

good job

[JJFormato]

Originally Posted by Sébast19X

good job

Thank you

[Sébast19X]

Jeremy, I'm curious, because test a vs test b include tune tweak. What would be the gain back to back at the same afr and same timing.

Did you told that this car produce better results from 12.5 to 11.95 AFR ???

Thank you for clarifying,

Sébastien

[JJFormato]

Originally Posted by Sébast19X

Jeremy, I'm curious, because test a vs test b include tune tweak. What would be the gain back to back at the same afr and same timing.

Did you told that this car produce better results from 12.5 to 11.95 AFR ???

Thank you for clarifying,

Sébastien

Sebastien, Jeremy has been up in PA and away from the computer to respond, as to why this car responded the way it did. When he gets back he will chime in.

Thanks
Dan
Fasterproms

[dfinke23]

How does the flow compare to the LSXr, or a normally ported LS7 intake? I still haven't seen anyone have substantial gains compared to a properly ported LS7 intake. All of the LSXr gains I see come from bigger injectors, then they don't test the same injectors in the ported LS7.

[Sébast19X]

The gain are not from the injectors itselfs. The gain are mostly due to the longer and better design runner and more plenum volume. Longer runner are prone to enhence the area under the curve ( better trq and hp coming sooner in the curve than the ls7 intake even ported.

But it would be interesting to see a bolt-on car stock cam with a stock LS7, Ported LS7 stage 1 , Ported LS7 stage 2. And also a stock or cleaned fast with stock injectors of course.

I know it is alot of job for the tuner or J formato, but it would be and interesting comparaison to help many of us who want more , but who are not ready for the LSXR.

Thank you,

Sébastien

[dfinke23]

Originally Posted by Sébast19X

But it would be interesting to see a bolt-on car stock cam with a stock LS7, Ported LS7 stage 1 , Ported LS7 stage 2. And also a stock or cleaned fast with stock injectors of course.

This could be done in an afternoon, I would love to see a tuner do this. I woulod be happy to pay for the port work with this kind of info.

[JJFormato]

Originally Posted by Sébast19X

The gain are not from the injectors itselfs. The gain are mostly due to the longer and better design runner and more plenum volume. Longer runner are prone to enhence the area under the curve ( better trq and hp coming sooner in the curve than the ls7 intake even ported.

But it would be interesting to see a bolt-on car stock cam with a stock LS7, Ported LS7 stage 1 , Ported LS7 stage. And also a stock or cleaned fast with stock injectors of course.

I know it is alot of job for the tuner or J formato, but it would be and interesting comparaison to help many of us who want more , but who are not ready for the LSXR.

Thank you,

Sébastien

Sebestien, that would be a great round of comparisons to do, and hopefully we can do that soon, but I would also add a ported FAST in there as well. It could be done in an afternoon. If we can make it happen I will definitely let everyone know.

Thanks
Dan
Fasterproms

[dfinke23]

Great, I can't wait.