How to make an Explorer intake presentable

[white95]

Well, I have this Explorer intake laying around and I've decided to make it look better. Ive noticed a few of our members are doing an Explorer swap and decided a nice write-up was in order.

The victim:

This process will take sometime, as I'll do most of this during my breaks at work. That way I have access to a parts washer, sandblast cabinet, air grinders, the central machine shop (complete with friends to make me stuff) and all kinds of sweet tools.

Phase 1 Scope:

To remove unnecessary vacuum ports, drill/tap/plug leftover holes, strip old powder coating and remove throttle cable boss

 

[white95]

First step will be a good soaking in the parts wash cabinet:

The second step is removing the old powder coat in the media blasting cabinet:

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[white95]

More progress on the way...

 

[white95]

Going to get rid of these also:

 

[white95]

Progress is slow but steady..

 

[white95]

Today, I cut that useless bracket off and begun the smoothing process. I used a sawzall on the bracket and for the smoothing, im using this:

 

[white95]

Made short work of the "raised circular things":

I removed the casting seam from one end as well:

I will revisit this later to completely smooth it out.

This will take a lot of time but eventually, you'll never know it was there:

 

[white95]

Random related pictures:

 

[white95]

I have been super busy at work with no spare time to finish this, I promise more progress very soon!

 

[MustangChris]

[MENTION=10188]white95[/MENTION]

:whip2:

 

[white95]

If I can squeeze some time in at work, I'll finish the few things I started. I'm on day 55 straight at work and have been exhausted lately. You should see my yard, it's atrocious.

 

[white95]

I havent sold this intake so it looks like I'm going to finish the project.