Well, I finally got off my butt and started smoothing out the intake runners. Here is the first one (took about 20 minutes):

The intake runners are a PITA to get smooth. The radius inside the runner changes. You did enough. Any more wouldn't gain you squat.

Your outlets to the heads are another story. You've left some pretty generous radiuses on the inside corners. That'* lost flow. Your head ports are a 2mm inside radius at most.

wouldn't it be nice if someone like Edlebrock made heads and matched LIM for the 3800?

Another point about the ports above is that they're not even. The cuts are somewhat jagged, not straight.

Heads aren't an issue. The restriction is the LIM. A dremel tool is cheaper than what Edelbrock would charge.

I could probably clean up those edges and corner radiuses a bit more, and I probably will over the next few weeks. The biggest "jaggy" is noted here with the red arrow...unfortunately, that'* a continuation of the casting joint indicated by the blue arrow, and I can't shave off enough to even that out without getting too close to my gasket edge:

Don't remove more material than the width and height of your head ports. The L36 LIM I ported came out smooth and straight, 0.9x1.9, and I had no problems with the casting joint.

Will,
I've been following this thread and also the thread where you talked about doing the test LIM'* . I have all my parts here and am ready to start dremeling away. Questions:

Will- Were the two test LIM'* sent to you? If so, what heads did you measure off of to get exact dimensions to grind the head mating ports on the LIM to. Also, what was your reference point? Meaning you took a measurement off the head, but how did you know what side of the port to take it off of to get to your final dimensions?

Agra- You laid the gasket down and traced with a sharpie and stayed away a 1/16th or so, so as not to create a "shelf" at the head. I laid down my aluminum gaskets on the morad LIM but it seemed there was a little to much room to move it around and still have everything lined up. I'm leaning towards this sharpie method as I can't afford the down time. So what is the best way to line up the gasket and be happy about making the trace?
Agra- This is off topic but I instaled the thrasher shift kit yesterday. Went real smoothe. Thanks for the PM. Had to add over 7qts. tranny fluid though :( . Must of been low before I did the install. Took many pics. Will post when I figure out how to do it with pics.

I measured EK98'* heads when I had his motor torn apart. Then I went to a wrecker and measured two other L36'*. I compared that with the 2 L27'* and my own L67'* for size. They're all the same.

Yes, the the LIM was sent to me.

A sharpie and a gasket are the worst thing you can possibly do. Your goal is to MIRROR the head ports EXACTLY. Ignore the gasket. Gaskets are not manufactured to the same specs as cylinder heads. Nor do they matter in the equation. They will trip you up, not help you.

Were all the ports on the heads you checked at the wrecker the same size as well as EK98'*? If they were the same then I should shoot for 0.9x1.9? Once again, what was your reference point when taking measurments and then grinding?

Sorry. Just reread the thread. You mentioned they were the same.