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This
modification is called knife edging. Most
manifolds these days come knife edged from the factory.
However if you have a flat front surface on the plenum
separator then you may gain a slight increase in
performance by knife edging like so. Mirror
polishing in this area also helps to reduce restriction
and improve flow. |
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This
is an un-modified KLZE inlet. Notice how in the
photo to the left the shape is no longer rectangular as in
the photo above. This is because there is a small
amount of metal in that area which can be removed by a
good porting machinist to allow a little more airflow.
Also notice how the edges have been radiused.. |
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This is called
hourglassing the butterfly shaft in your throttlebody.
Many tuners opt to purchase an aftermarket larger bore
throttlebody. But the larger diameter bore radically
modifies the airflow at low RPMs and often negatively
effects the range output of the throttle position sensor. |
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This
makes it very hard to get a good idle.. The hourglass
mod preserves airflow at idle while improving top
end flow because modification becomes more effective as
the throttle approaches wide open position. |
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This is an
un-ported KLZE Intake port looking in from the flange.
There is a lot of improvement that can be made to improve
stock intake and exhaust port flow on a KL motor. |
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And here is the intake port
after porting and a mild polish. Note the knife
edged divider. Note: This kind of porting work
should only be done by experienced head machinists.
It is very easy to damage a set of heads if you do not
know what you are doing. |
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This is how a good head
porting machinist will know where his limits are.
This is the only way to be sure of the limits. |
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This is a porting template
sitting on a KLZE intake manifold. This is how a
manifold is exact port matched to a set of heads.
This reduces flow restrictions in the intake ports. |
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This is an inake manifold
runner after template port matching and mirror polishing.. |
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Many people are falsely led
to believe that putting a ZE intake on a KL01 engine will
improve power. But as seen in the photos above
this actually creates huge obstructions in the airflow
path and reduces low to mid range horsepower. There
are some very minimal top end gains because of the reduced
restriction over the long path of the runners. But
when the flow reaches the head it has the same restriction
it has with the KL01 intake. |
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Notice the dimples in the
injector recess. These are called injector
turbulators. Some believe the theory behind
turbulators is that as the fuel micro-droplets disperse
away from the injector the turbulators re-direct the
droplets back into to a convergence point where they
collide and atomize into a fine mist. |
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Others believe that it is
the turbulence they create in the flow path that causes
the fuel droplets to further atomize. Thus is the
reason for their name. Turbulators can be either
protruding or dimpled. |
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The recess machined lip
around the valve seat in this photo is called
de-shrouding. This increases the effective distance
from the valve tulip to the chamber wall which allows more
airfuel mixture to enter the chamber. When valves
are shrouded by the chamber walls the flow is restricted
in that area. |
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This is how to CC a set of
heads. A clear piece of Plexiglas is glued to the surface
with a small hole in it to fill the chamber with a fluid.
Then the fluid is measured in each chamber and recorded.
Material is removed from the smaller chambers until they
are all equal in volume. |
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This is a polished
combustion chamber. Polishing reduces hot spots or
chances for pre-detonation in high compression or forced
induction engines. |
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Polishing the valves also
reduces possible hot spots and reduces carbon build up
potential. |
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This is a KLZE port matched
KL01 intake manifold. Some very good potential can
be unleashed from a KL01 intake manifold. The
KL01 intake manifold has some very good torque
characteristics so if you increase the top end with some
extensive porting work then the best of both worlds can be
obtained. |
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This is a solid lash adjuster from a 2000 and up Mazda 626
KLG4 2.5L motor. Mazda replaced the hydraulic versions
in the late model engines to reduce valvetrain noise from
sticky HLA's. These can be a good performance increase
if used with some custom grind high lift and extended duration
cams. |
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KL01 Rod to the left,
Millenia "S" miller cycle rod in the middle and Small
Block Ford 5.4"length rod to the right. These are
just a few rod options for the KL motors. |
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This is a highly modified Millenia "S" rod on the left
compared to a stock one on the right. The one on the
left has been lightened extensively and the beams were
polished to eliminate stress risers. |
Removing the casting flash
and polishing the beams on the rods removes possible
stress risers which could lead to rod failure under power. |
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This is a meticulously
balanced set of rods with polished beams. They are
balanced to within a half gram of each other. It
is ultimately important to balance an engine well
anytime you alter the original rotating mass. If
balancing is skipped then a catastrophic failure is very
likely! |
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