Also I'm trying to decide if I want to try to really polish up the ports or leave them a bit like they are now. Suggestions for either one? I did slip a few time at the start but this plate it trashed so it doesnt matter very much.

 

Best Advice i can give you (Being a bit of a Port Noob myself)



Is, paint the Port area with mat Black first and use a Scribe and Rule to mark up your origanal port, then work off that to mark up your Bigger one.



Also You can Put a corner seal in a rotor and run it round the Port area so it cleans off the mat Black where the Seal contacts the Plate, so you now have a guide how far you can go.



The Oil seal side of the port (inner closest the center of the plate) should only be Cleaned up don't remove any more than you have to.

 

as for removing Metal.



You oviously have a Die grinder with a Bur for Roughing but i use Abrasive Cones (40's and 80's) for smoothing out and Finishing. Also once its all marked up Put a few layers of Duck tape around the Port Area slightly bigger than the new port size, so if you do slip you have more of a Fighting chance of saving the Plate.



Hope this Helps.

 

all in all, they look good to me. Grizzly gave you some good advice.



the onlt thing i'll add is as far as the finish is concerned, even if you're not one for "mirror" polishing ports, i'd say smoothen them up more than what you show in the photos you posted.

 

I recommend starting w/ an aluminum oxide 40-60 grit grinding stone instead of the burr. The burr is far too aggressive and can leave some serious pits in the runner and the port outlet.



B

 

used this from summit... works great on the runners