EMPI Head casting flash removal

[Bryan Cotton]

Short video showing some before and after.
https://youtube.com/shorts/TjH-AbOVecs

[Bryan Cotton]

Sanding tool in action. The disc is .020" 7075-T6. Skinny and stiff is the key. Skinny to fit between and stiff to be able to sand effectively. In the picture I am pulling down to sand. I've just flipped the disc over and will push up to sand.

[Bryan Cotton]

Here is another key weapon against flashing - a cutoff wheel on a 1/4" mandrel for your drill. Lets you get all the way to the bottom of the space. Also when the fin misalignment prevents sanding disc entry, this is a good first pass.

Screenshot_20240819-222007.png (1.04 MiB) Viewed 517 times

[Bryan Cotton]

Center slot before:

Here it is after. I used a hacksaw blade holder and small files.

Here are the passages through the head around the exhaust valve before.

I've seen pics of this area really opened up, but I don't think you can do much more with the EMPI heads than this.