porting the exhaust manifold

when you port your exhaust, how deep are you suppose to venture into the manifold? same question with o2 houseing. also. evo manifold for 4g63 $199. worth the money? or waste of $?

Depends on what part you mean. For the manifold, int he inlet side just take otu the step for 6cm turbos, or take it out to a 7cm gasket for the 7cm turbos. Take it all the way through that lip, and knifeedge the divider as well. In the runner side, just take it in enough to get a gradual enough taper. 2-3 inches would suffice.

For the O2 sensor, same thing. Just take it all in far enough to blend it well. The idea is you dont want any abrupt changes, they will affect airflow.

EVO mani is good if you want to save some time. Its almost already ported out to 7cm size, saving a couple hours of port work. Just have to remove the step. The runners require about the same work as a 2g mani. Wether or not its worth it is up to you, and how good or bad your current mani is. For example, a 1g guy that has to buy a 2g mani anyway would do well to pick up a evo mani instead in most cases. Etc.

what do i need to buy at sears to do the job right?
im adicted to tools. any chance i get to buy a new tool, i'll do it.

I use a walmart 20 dollar campbel housfield die grinder (for air compressor) and some carbide burs from www.mcmaster.com. I wouldnt use any other setup. If for some reason you REALLY cant use a compressor, sears does sell an electric die grinder for about 80 bucks, but they suck in my expereince. Only the very expensive grinders are worth it. And those still die too. Either way, dont use some hardware store bits, get real double cut carbide burs, typically in 1/4 inch shank to match the grinder.

To get you started a 3/8th pointed tree is good for tight spots like O2 housings, but a 1/2 cylindrical is better for removing a lot of material where you have room to work. They're about 10-15 bucks each, but I would recomend at least those two sizes. I think thats all I use...