Is there a definitive 'how to' or guide anywhere that details how to go about this?

For those that have done it would you advise i give it a go or not to even go there?

As i'm not mechanically minded at all i'm looking for things to do on the car for me to have a go at.

pain in the ass but here is what zedwizz sent me when i asked him

 

Here is a quick guide for you. To polish the plenum you will need to remove it from the engine. To hold it while I polished it I made up a ‘T’ shaped jig out of a piece of wood so I could screw the plenum to it and clamp the wooden jig to a bench. It also makes it a good height to work on. I can take some picture of the wooden jig if you need.

 

Next I used a 6-inch sanding disc (120 grit) to quickly take out most of the flashing and casting mismatch. I have something like this

http://cgi.ebay.co.uk/3-In-1-CAR-POL...item1c15b7747e

 

Mine came with a 6” Velcro pad, which can take 6” Velcro backed sanding, discs like these

http://cgi.ebay.co.uk/SANDING-DISCS-...item2ea8a6a9c8

 

The 6-inch disc can be used to get most of the flat surfaces and makes short work of the dimpled affect also you can make sure everything is kept nice and flat. Some people use a smaller disc but you will end up with lumps and bumps, which show up when you get to the final polishing stage.

 

 

 

 

 

 

Next I used a die grinder like this with and 2 inch sanding disk to get in all the nooks and cranes

 

http://cgi.ebay.co.uk/PROFESSIONAL-1...item2c5485acb2

 

Then it is down to sand paper and finger power. Once you have all of the plenum smoothed down to 120 grit use wet and dry in every finer grades and water with a little drop of washing up liquid in. When the plenum gets a dull shine to it its time to get out the mops.

 

I brought this kit

 

http://www.frost.co.uk/item_Detail.a...ts&subCatID=49

 

All you will need is an electric drill and loads of time lol. Start with the course mops first and work your way to the cloth ones. Don’t use to much soap at once.

 

 

 

Hope this helps.

Figured that might be the case. Still interested in the process though.

above you were too quick

You dont have the skill or the patience :lol::lol:

You dont have the skill or the patience :lol::lol:

 

i think he just said something similar to that himself on another thread

You dont have the skill or the patience :lol::lol:

 

I think you might be right. I'm hoping to aquire some. PMSL :biggrin:

dont come here asking for any. just got enough for myself :lol::lol:

Think i'll just design and build a new boot set-up. Forget about the practicality of getting to the spare and go 'all out' on one.

I have just finished my plenum and i would quite happily state, that i will never do another :laugh:

Its very time consuming and laborious. I did mine a few hours everyday for a few weeks and did everything with power tools and cutting/sanding/mopping wheels. If i had done it by hand i would still be only half way through lol.

 

To start: ( assuming its already out of the car) remove the throttle bodies, pipework, balance bar and vac outlet points. To take down the casting marks/lines i used a power file for the inner legs of the plenum and an orbital for the flat surfaces. Now the secret to minimising work for yourself is not to go at it too harshly, leaving score marks everywhere, which will take an age to level down. Start with an 80grit and work down to finer grits until the surface feels smooth. I bought myself a paint/rust removing wheel, which is like a heavy brillo pad with metal filings impregnated, to go over the surfaces and get rid of any pitting, then used a brillo wheel to make it finer again.

The using a sisal wheel with aluminium cutting bar, i got to work on polishing. I spent days and hours at this stage, before moving onto a softer wheel with a red bar which gets rid of tiny scratches created from the first wheel. The a soft polishing wheel with a blue bar for the final polish.

 

Its not just the plenum i polished, but the throttle bodies, hex head bolts, the TB springs and connecting bar, AAIV, FICD etc.

 

It depends how far you want to go really, but ive had the luxury of time and having all the spare parts from my new engine to work on, while my car is still on the road.

 

There are a couple of write ups around.

 

So time consuming and alot of effort, but well worth the result IMO.

Cheers groover. You have convinced me it's not really for me. Might look into the colour coding option instead!!

Cheers groover. You have convinced me it's not really for me. Might look into the colour coding option instead!!

 

:lol::lol:

 

 

At least have ago. if it dosnt work then get it sprayed :wink:

There are plenty of companys that will polish it for you, I came across a local crap one and had to do mine again, but have a look around local companys and see what you can find!!! I basically started from scratch with mine as the job was poor and it is a time consuming dirty job!! if I was to do one again I would get a pro to do it as mine is still far from perfect, its very hard to get in all the nooks and crannys! :huh:

Cheers groover. You have convinced me it's not really for me. Might look into the colour coding option instead!!

 

If you get it sprayed, its still worth sanding down the casting marks on the top legs.

I reckon I might find it theraputic. Trying to stay out the boozer and need things to occupy me, only so many times I can set up my Bspec driver, look on eBay at sh*t I don't need or want, and constantly push the 'new posts' icon :helpsmilie::bored::helpsmilie:

I think you need to go for it Daffy!

 

I'm glad i'm not the only one who spends most of their time browsing through stuff on ebay that i dont need and constantly clicking on todays posts.

 

I would like to do it as ive realised its going to be about 4months till i clear my debts so its something to do over the months which will make me feel like im actually improving the car whilst not spending more funds.

 

only one issue. i dont know how to remove the plenum.

Lots of info on the plenum pull, start here, there are also links in the write up, not too difficult.

http://s95014253.onlinehome.us/63104/16304.html

Thanks mate!! bit of bedtime reading

A worthwhile mod to do as a starting base to bling up the engine bay lol

 

Happy reading :thumbup1:

Well that article has just set back my plenum removal by a few weeks, need to wait for all my appropriate hoses and stuff, most of which I can't afford now until July :( Oh well, have to put up with lumpy running for a few weeks I guess :(