Paul,
As of today I have bored p ports both ways, straight thru one size
and/or  with a shoulder.  Of the two, the shoulder version finishes
off perfectly inside the housing as you have said  and for that
reason I think it is better.  I am happy to report my  little fixture
was adequate.  No vibration at all even when I hit it with big
tooling.  This time I bored a 1.5" dia hole with a six flute HSS end
mill  and then finished with the boring head.  The job went slowly
due to the amount to be removed.  If I end up doing more of these, I
will buy a 1.75" mill.   Other than that, no problem.    If anybody
wants to do their own, I will be glad to offer verbal assistance.  I
do not have any 2" aluminum tube so I stuffed a steel exhaust bend in
the hole to see how it looked.     Not bad.      Jerry

Sorry about the clutter.  That is how my desk always looks.


Good work Jerry. How much would you charge?
I think it would go faster if you drilled it one inch dia. first
to give clearance for the end mill center.

Paul Lamar ...No rotor no motor.

What do  you think about me making and installing the inserts too?
The  logical package is one that is ready for the slide throttle. Not
to mention that I got a new tool post and  holders today that I am
itching to try out.   Could  you send me a drawing of the inserts.
Thanks    Jerry

Fine with me. The drawings are on the web site.
http://www.rotaryeng.net/intake.html

DXF maybe. What does you drawing program import?


Paul Lamar ...No rotor no motor.

Paul, I looked for the drawings but could not locate.  I think I
opened every file under "Intake Systems."  Jerry

What is on the web site is a jpg of the drawings.

I sent these out on the 22nd but here they are again in DXF zipped
form. Perhaps your ISP does not like zip.