Grab the ported cylinder and line it with a piece of paper cut flush to the top and bottom. Get a soft pencil or charcoal rubbing stick and make a rubbing outline of your porting layout (Port Map). Remove the paper and cut out all the port window tracings then install it in the UN ported cylinder aligning the side and exhaust ports being sure that the top & bottom are flush to the cylinder. Now you can transfer the differences using a sharpie or machinist's blue dye. Just like stencilling. Now the image of the ported cylinder is transferred to the stock one. Use aluminium oxide 120 grit sanding drums to slowly remove material. Be aware of rotational creep of the drums opposite the direction of the drum rotation as this tends to make the straight lines bend. Keep the sander moving along the material to be removed. When the port windows are done. Cut some 600 grit emery cloth into strips and drag them through the North and South edges of the ports where the piston rings travel to prevent ring hang up once the motor is assembled.thank you for all of your help! I'm going to be working on them over thanksgiving break, as I'm off at school and no where near the sled or motor right now.
anyways i have a few more questions, is this porting legit...will the motor actually be putting out more hp(or be more efficient)? if so would i need to adjust the jetting and clutches?
also what is the best way to make sure the ports are the same shape and all...i mean i can get the proper dimensions but how do i make sure that the curves on the lower parts of the ports match? eyeball it?
PS sorry about the blurry pics...that was either my father or younger brother taking the pics ...i haven't been home in a while.[/b]