Today i started polishing out my intake manifold while still installed on the car. Its gonna take a while, but i did manage to get one of the ducts sanded and polished out. Now it matches up to my valve cover perfectly.

Do it yourself:
Im using a 80,100(dry)220,320,420,600,800,1500(wet) sanding process. Im buying a dremel tool to speed up the 80-100 grit stages cause its kinda tough getting the metal totally smoothed out by hand. Then im doin all the rest by hand.

Ill post pics soon!

 

Let me know what you think of the Dremel tool after using it for a while. I tried one for a few minutes on my valve cover, but got so aggravated with the life of the sanding drums that I gave up. I was planning on doing my intake while on the car also, but I was going to use a die grinder in one hand and a shop vac hose in the other.