Turbo Regal Intercooler Neck Porting

by James West

Go to a NAPA store and buy some 2 inch diameter, 80 grit welding flap wheels. I would suggest buying 3 or 4 of them. I started with 60 grit wheels, the material comes off really fast and creates a lot of heat. If not careful, you will have a hole in the inlet before you know it. I used a industrial, high speed electric dermal tool. The one that has the motor mounted on the far end, opposite of the chuck.

I found that mounting the intercooler upside-down in a vise works best while doing the work. Use some pieces of plywood between the jaws of the vice and the intercooler to keep from crushing it when tightening it in the vice.

Stuff a shop rag in the intercooler inlet opening, past the elbow. I know this sound strange but it needs to be pushed in around the bend to keep the aluminum filings from getting inside and so that it doesn't get ground up by the flap wheel. Also close off the outlet, you won't believe where you will find the filings when you're done.

To port the inlet, start at the outer edge and work towards the bend. When finished the outer edge should be tapered like a knife edged. Tell him to work slowly and don't get it too thin. On the outlet, I'd just go in an do a quick polish from the bend out. You really won't gain much there, only make a bigger mess.

When finished, turn the intercooler on it's side, with the inlet side up. Blow compressed air from the outlet opening back through the intercooler and out the inlet side. Flush with water. I usually take mine to the car wash and use the high pressure water. You could also follow the spring cleaning guide and pour a large bottle or two of oxygen sensor safe carb/fuel injector cleaner in and let it soak, then take it to the car wash and wash it out with hot, soapy water then rinse it several time using the high pressure water. If you have a shop vacuum, hook the hose to the vacuum outlet and blow back through the intercooler till it is dry. If you don't have a shop vacuum then turn the intercooler on it's side and set it in the sun for a day or two. In weather like this, it won't take long to dry.

* Make sure you turn down the boost level because this modification will raise the boost a few psi.

Optional porting tools (Steve Monroe):

Use a coarse tooth rotary bit for soft metals like aluminum.  My favorite is 1/4" shank, 5/8" diameter tapering down to 3/8" and has about 8 teeth.

Part Number 4295A63: Clog-Free Carbide Bur 14 Deg Taper-Radius End, 1/2" Head Diameter, 3" Oal. Catalog page 2304. $28.08 Each.

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