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Continuing to plug away at this. I got the block back right side up and began scraping off the remnants of the intake manifold gasket from the engine and the intake. I would love to gasket and port match everything, but that is a later down the road project. The intake gasket has a good sized gap on all sides of the intake and head, but I did a paper traced overlay to compare the head to the intake and it was actually closer than I had seen in online photos, perhaps the GEP quality control has tightened that up a bit.
I did notice on the intake manifold there were a few casting flaws where there was a slight edge to the intake manifold that formed sort of a shelf. I chucked up a sanding tool in my dremel and ran it around the intake manifold ports on all sides. I intentionally didn’t really take any meat off, just got the casting flaws gone and smoothed it out just a bit.
The rest of the intake has a “sand” finish on the inside; I don’t think it is necessary since no fuel/air mixture is traveling through there, just air. I don’t know if I will smooth it out, probably another later project.
Anyway, some pictures of the intake “porting” work, notice the before and after of the runner with the worst casting flaws.
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