Ok, I didn't post this in the "HOW TO" because I am not an expert and I am not posting this as a step by step directions on how to do what was done.. Now with that being said..
I was able to get 6 hours free this weekend so I got busy on my tumblers.. My motor came in last week all worked over and ready to be dropped in so I wanted to get all the misc odds and ends ready for install day.. Since I had the tumblers already removed from the old EJ20 I decided to de-butterfly them and port them.. I didn't see the need to pay 250 bucks for some one else to do this so I did it my self..
First I took off the sensors on each end of the tumbler body.. The smaller sensor ready the position of the butterfly valves and the larger is the boost actuated motor that operates the tumblers.. Once the sensors were removed the small bolts that hold the butterfly valve to the rod had to be removed.. Caution was needed here since the bolts are "Peened" over from Subaru to prevent them from backing out over time.. A small carbide tip cutter was used to grind the end of the bolt till it was flush with the rod. Once that was achieved a #2 flat head screw driver (Craftsmen Only)
works well to back out the small brass screws. CAUTION: The screws will round easily, make sure you us a good screw driver and apply pressure against the screw when backing them out..
Once. The butterfly assembly was removed an issue arose.. "What to do about the holes".. An option was to leave the sensors in place but with the higher boost levels will the plastic be strong enough? The decision was made to make end caps out of aluminum.. My Milling skills are not the best as I don't run the milling machine often, but I am kinda satisfied with the results.. I even got my girl friend in on the action.. What is hotter then a female "Steelers Fan" all bundled up to help out in the cold machine shop working on the WRX?? After that issue was conquered I moved onto the Divider that allowed a moderate amount of air to bypass the butterfly valves.. For this task I again turned to the milling machine.. Once I milled the divider out I grabbed my die grinder and several assorted sizes of paddle wheel sanding disks.. I worked in stages and in areas with the proper size wheel to achieve a smooth consistent taper across the tumbler body.. I am happy with my results, I am not sure as to the flow ratings, or the consistency between each port..
Hit me up with thoughts and comments.. If any one is looking to get their tumblers de-valved I am more than happy to help out...