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General Category >> Rubber Side Down! >> Opening the Exhaust Port
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Message started by Ed L. on 02/23/08 at 15:48:13

Title: Opening the Exhaust Port
Post by Ed L. on 02/23/08 at 15:48:13

I know there has been a lot posted on how to open up the exhaust port on the head but has anyone tried it with the head on the engine and still in the bike? It looks easy enough, just pack towels around the valve stems and go to town with a dremel or small grinder. I know the results won't be as good as a dissassembly and polish but what the heck anything has to be better than what is there. I would think that in the search for "free" horsepower this would be a must. Whadda ya think?

Title: Re: Opening the Exhaust Port
Post by KwakNut on 02/24/08 at 03:47:09

I think Lancer did exactly that - he published pictures somewhere on here. Although you would ideally want to get behind the valves to de-step the seats, the biggest problem with the Savage head (and where the material needs to be removed) is just inside the exhaust port exit, so you should be able to do 90% of the important work and get rid of that ridiculously restrictive cast-in aluminum neck in situ.
There are some pictures of the porting I did here:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1200747403/0#0
Not sure where Lancer's thread is, but it shows similar work with the port behind stuffed with cloth.
I'd recommend setting the motor to TDC on compression so you can be sure the exhaust valves are closed, then you can blow out any waste after with an airline and not worry about sending it into the cylinder.

Title: Re: Opening the Exhaust Port
Post by Ed L. on 02/24/08 at 06:41:21

That's just what I was talkng about, thanks. Doesn't look to hard to do think I'll give it a try. :)

Title: Re: Opening the Exhaust Port
Post by justin_o_guy2 on 02/24/08 at 08:20:04

I took one of my blowers & removed the tip[screw in] & drilled it out to acept a small piece of brass tubing, I think it was 1/16th ID, if bigger, not a lot bigger, with a small flare on the inside end & a dab of JB Weld, its In There. It goes in behind things & blows stuff out, also, the tip can be bent a little. I guess if a guy needed to badly enough, a tip that blows back could be built. Good luck with the project Ed.