There is more than enough material left, it is a fairly thick casting. Just a rough guesstimate is that between 1/3-1/2 the thickness of the casting remains at the thinnest area.

 

If you saw one of Mr HP's ported intakes you would see there is actually a lot more material you can safely take off. Where the carb mounts up he hogs out much of the material to where it is about half the thickness of what I see in those pics. Matching the inner diameter of the carb side to the actual size of the carb being used is the most important factor when porting the intake. You want them to be as closely as matched as possible.

 

Yes that is correct, but this was ported for a stock carb, that is why there appears to be more material than MrHP's mani which are ported for 45-48mm carbs. I just started one for a TM45 carb yesterday, I will post up pics of that one when it is done.

I had measured the ID of the carb's outlet prior to porting the inlet of the mani, and then also matched the outlets of mani's runners and the ports on the head to each other.

 

Another part of the intake that gets totally ignored when the ported intake mani is installed is the flexible coupler between the mani and the carb. The inside of the stock coupler can be resized with a dremel sanding drum.

The new battery finally arrived(pc545) and I was able to take the DS for a quick spin this morning to the top of the mtn and back down. There is a very noticeable difference with the ported mani, almost instant throttle response, and what feels like more umph through out the rpm range, now I just need to snag a BigGun cdi box.

 

Here is the mani I just started, it is ported out to 45mm, just have to finish blend and texture the internal surfaces with Black Diamond blasting.

 

Are you doing these "on the side"? And for how much if so? Can you do 48mm?
Thanks

 

We can arrange something...pm sent

 

I just did this one this morning, it is roughed out to 47.5mm, final blending will take it to 48mm.

 

gotta love the ingenuity of the people in here !!!

 

What kind of tool are you using to grind that down?