Hey guys what is the best tool/tools people have used for port matching the plenum (alloy) and the minifolds ( cast steel )?... Cheers, Steve
Air powered and electric die grinders with tungsten and silicon carbide burrs . You have to be careful though as they can turn your parts into scrap very quickly.
Google - Standard Abrasives Deluxe Porting Kit. One kit box is sufficient to do plenum, heads and exhaust manifolds.
I used an 80grit flapper wheel and a dremel. The alloy is soft on the upper and lower plenum's and easy to shape.