Tools Needed
-Automotive Wet/Dry Sandpaper in the following grits
-220
-320
-600
-1000
-1500
-2000
-A 1/4 sheet electric (or air if you have it) sander from Home Depot or something similar, they are like $30 (you can do this all by hand but trust me it is easier and less time consuming with the sander)
-Mothers Metal Polish (or equivalent..I like Mothers)
-A high speed buffer with a pad you can ruin(this is optional too but you will get better results if you have one)
-Metric Allen wrenches
Procedure
I recommend taking the manifold off of the car, you can do it while it is on, but it will make a huge mess as well as get metal *bits* everywhere. Also, if you leave it on the car, it is much harder to get into all of the areas with the sander/and or by hand with sandpaper. That being said.
Removing manifold
-Take of engine cover
-Remove 2 bolts holding fuel rail to manifold
-Gently pull up on entire fuel rail towards you, injectors and entire fuel rail should remain intact.
-Move fuel rail/injector assembly over to the side out of the way on a towel on the passenger side of the car.
-Remove the hose from the throttle body
-Disconnect all plugs and vacuum lines going to the throttle body and intake (take note where they go back.
-Remove the bolt for the manifold support bracket (underneath)
-Remove all bolts holding the manifold to the the head of the car (should be eight of them)
-Remove manifold from car.
The whole reason we started this whole thing
-Find a piece of wood (or a dining room table you dont care about) and sheetrock screw the manifold into it like you were mounting it back onto the car.
-You know have a steady manifold on a piece of wood to work with.
Polishing
-Depending on what size sand paper you bought (1/4 sheet or full sheet) cut to size in order to fit on the sander.
-Get out the water hose and get it ready
-Start by putting the 220 grit onthe sander.
-Wet entire manifold by spraying it with the hose.
-Start to go back and forth on the manifold slowly cutting the *grain* out of the manifold. When the water starts to get dark colored, rinse with hose.
-Go over the complete manifold several times until the *grain* is completely gone by repeating the rinse/ sand cycle.
Make sure to change the sandpaper frequently, once you become familiar with it, you will know when it needs to be changed.
-Once you are happy with the amount of grain you have taken off (should be much smoother) move onto the next grit
-Go over the entire manifold with 320 using the same steps above until it is as smooth as it can get with that grit.
-Repeat all steps with ALL grit..DO NOT SKIP ANY GRITS OR IT WONT TURN OUT RIGHT!
-Once you have gone through all grits, you should have a really fine finish that looks like brushed aluminum, if you see deep scratches somewhere, you need to go back through some of the grits or you wont be happy with the outcome.
*ATTENTION TO DETAIL NOW PAYS OFF LATER*
Polishing
-Once you have the surface desired with no deep scratches/imperfections you are ready for the final polishing.
-Take a paper towel and put a thin coat of Mothers Metal polish everywhere on the manifold (at least where you sanded)
-Take the high speed buffer and run it back and forth on the manifold until the polish starts to turn really black.
-Wipe the polish off with a rag and start to see the shine.
-Apply more polish with a paper towel and repeat the above process until you get the desired effect.
Reinstallation
-Well, it really is the reverse of removal =)
Enjoy the final product =D
I cant stress enought that this should be done off the car, it really is messy and you will leave bits of aluminum EVERYWHERE.
Also, your attention to detail between grits will pay off dividends if you make sure the surface is as smooth as it is gonna get before you move on, if you think you will get that spot that you missed on the next go round, trust me when I tell you that you will be mad at yourself for not doing it when you should have... (from hoTTub)
should turn out like:
<img src="http://pictureposter.audiworld.com/50091/img_0002-1.jpg.jpg">
Good Luck, Just ask me if you have any questions