While cleaning the dirt, grease, and oil off of my upper and lower intake manifolds I noticed that the inside of the manifolds is pretty rough. I've been thinking about taking some sandpaper to the insides and smoothing out and then polishing them to remove the rough cast finish. I imagine the airflow would be less turbulent if the sides of the runners are smooth.
Let's imagine all I did was smooth out the insides and bolt them on; no gasket matching or porting. Would this make any noticeable difference in power or efficiency?
Another question: Once I get a new dremel I'll probably get some nice carbide bits and match the manifolds to the gasket that goes in between; how far into each port should I smooth the transition?
Is there any way I can screw something up by trying to do these things?

-Steven

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yes, smoothing will help. I cant say if it will be noticable.
with the dremel - as deep as possible.
yes, you can screw things up. the biggest thing to avoid is a step in the peices that is against the airflow, or removing to much material, so the gasket ends up sticking into the airflow. it can be trimmed down, but you have to know its there first....