I have a 97 Ram 1500 Ext. Cab 4x4 with the 5.9, and I've been searching all over the place for the last 3 days about detailed info regarding the throttle body mod, but nothing really mentions anything about porting the TB. I grasp the general concept, but how far can I go, and how do I know when to stop? Do I just measure the diameter? I drew a line where my butterflys sit, so I know how far down I can go....I'm just not sure how wide?

 

You want to go 52mm and go all the way through. What are you using to bore it out?
I believe it's best to get 2" throttle plates to replace yours when you bore the TB out to 52mm. I'm not sure if you can use the stock plates after the mod.

 

Well, I'm sure the best thing to do as far as boring it out, would be to take it to a machine shop, but if there is another way to do this in my garage, I have a complete set of sanders, and grinders for both drills and a dremel, all shapes and sizes, but no drill press.

 

One guy did it with one of these http://www.summitracing.com/parts/WMR-W193C/?rtype=10
It'll take a little while but it will work just fine. After honing it out you can take the dremel and knock the flutes off and round off the edges of the bores.