I just finished porting the upper plenum on my 2.8 project motor, and am in the process of porting the middle and lower intake manifold. The motor isn't finished, so I can't give any performance info. But when I placed the gaskets on the manifolds to mark them, there was quite a bit of metal to be removed.
The walls of the intake runners (where the plenum and middle manifold meet each other) actually curve inwards as they reach the mating surface. The middle and lower intake manifold do something similar where they meet each other, but it's more of a slanting inwards than a curving, if you know what I mean. This causes airflow restriction where the manifold pieces meet each other. Removing that restriction should yield an improvement in performance. But it won't be anything earth-shattering. Maybe 5-10HP at the most.
I'm doing the port work myself, with die grinder bits, cross-buff bits, and a fast drill. So far, I've invested roughly 12-16 hours of labor just on the upper and middle manifolds, and I still have yet to finish the lower manifold and cylinder heads. I anticipate spending about 40 hours of labor on this. No joke. If you don't have the time or patience for this kind of work, I'm sure you could get Extrude Hone to do it for you.
[This message has been edited by Blacktree (edited 08-23-2002).]