MOPED ARMY

ask chris paz of the creatures of the loin he is a master of case matching, use a dremil

Use a rotary type grinder like the dremel. I like to use 'A'

to cut into aluminum the teeth don't load as much and it cuts a lot faster. Depending on how aggressive I get I can port match a case in as little as 15min with it.

For best results use a gasket to trace the ports onto the case. There is a slight issue with the metra 65 kits, the ports are a bit lopsided on the kits but not on the gaskets. I just ported my first 65 metra case a few weeks ago and I matched the gasket (aluminum one) to the kit and then the case to the gasket to the case.

As for the actual case grinding, it depends. From the feedback I have received from the cases I have done the more of the original material you leave the better your mid range will be. If you profile the ports all the way to the back of the case you will improve the flow but it will show up more on the top end.

Get comfortable with dremeling first I really like the extension, holding a something shaped like a pencil vs something shaped like a brick has a lot to do with what the final product will look like.

When you are ready to attack the case I like to hold the dremel so that I will make a 45 degree cut into the case. I go around the whole port window and open it up to within about 1-2mm of the final dimension. This will allow you to clean up the port without going oversized. After you go around the port at a 45 degree angle you will be left with a steep transition. I then go back and round over that sharp angle and smooth it into the original port shape.

After you are done smoothing the port go back and open it up to the final dimension.

Little sanding and your done.

Thanks for the props Elliot!

I need to film the next case I port...

Here is a shot of the Malossi kit with the gasket laying on it.

Here is the gasket on the Moby case (parts of the old gasket show on the right - a little confusing)

So Professor Paz, do I want to take any additional material off the kit, since the gasket is a little bigger, or jsut leave that and match the case to the kit (primarily at the triangular areas at the top)?

You want to kit to match the case as close as possible, the gasket is the best way to do that. I you notice obvious differences with the gasket and the kit then take those into account. I would just leave the sides of the case alone since it looks like there is a little hang over on the case and the kit.

I would go alter the upper part of the case and leave the rest of it mostly alone.

Oh i forgot to mention originally that after you trace the gasket take the studs out of the case and keep the case halves together. You can access the case from any angle without the studs and you will end p with a smooth transition between halves if you leave them together. Learned that the first time, ported each half separately and when they were put back together the profiles did not match.

I video would be PRIMO chris.

Thanks for all the info already.

i feel like case matching should be easier than porting. Is it just as simple as putting the new gasket on yer case, and grinding away until they are flush? This idea seems friendlier, because you just open the case as close as possible to match the ports on the cylinder, and the amount of material and places you are supposed to remove material from are clearly highlighted by the gasket.

Porting seems harder and scarrier cause there isnt a friendly guide to help you, like the gasket. You have to do it and do it right the first time or your done.

is there any truth to that?

Mike, that's why I was wondering what Paz was referring to -is he taking the case halves with everything removed, and just putting them together to do the matching - then taking them apart to clean it all out?

That makes a lot more sense - I couldn't imagine doing that grinding with the crank still in there!

Since I'll just be doing the transfer ports I think I'll do it while the hlaves are apart - no profile to match.

clay thats interesting. i have used socks and tape personally with no problems.

i did 3 with the case together no problems so far

hey chris,

well I need to case match my metra kit as well as rebuilding the engine. Maybe when I come out to SF we can videotape the whole process for everyone, what do you think, a total engine rebuilding case matching tutorial! I have a couple of split cases ready to go....

i know it looks scary but it cleans up real easy ,only part thats hard to get it out of the stud holes but i should have removed the studs and pluged them holes.

paz i got e50 halves that need matched to polini. i'll call ya wen its ready if u want to do a vid

Ha, I have shot some pellets and 22s into that stuff too. Interesting mushrooming patterns

Great info. The pictures really help me understand what to expect.