When drilling and tapping exhaust manifold , those that have done it , did you keep the engine running while doing the work to blow out any chips being created? I need to do it next week and want to be as safe doing so as I can. Any advice?

 

Lots of people have done it lots of different ways, and have all seemed to have success with whatever way they have chose. IMO, working on a running engine is dangerous, too many hot and moving parts for me. Use a quality drill bit and tap, use cutting oil on the tap, and remove any shavings with a small magnet. Put anti-seize on the thermocouple threads in case it ever fails, will make it easier to remove and replace. My .02.

 

Here's my.02. It's kinda long but maybe it might give you a better idea. What ever you do, just make sure there is no metal fillings/chips left inside the exhaust man., if there is you'll find out soon enough.
I drilled the hole with two steps down from the recommended drill bit (been awhile and can't remember the size) didn't go through, very carefully drilled til I just barely broke in/through. I did the next step up drill bit the same way. Then with the tap til I hit the bottom of the hole that I didn't go through. I then used my shop vac to get everything. I then used a drill bit that I used the second run being careful not to hit the threads and drilled through ( I dipped the drill bit in grease 1st to catch the fillings) after drilling through, I used q-tips dipped in grease to pick up what got through(found a few).I packed the hole with grease so no metal filings would get through, with each process I cleaned the grease out with q-tips, I'm very careful. I'd rather spend the time doing that than replacing the turbo 'cuz I didn't get every piece out. I had the tap covered in grease too and while tapping (like a couple turns), I'd clean the tap with brake cleaner then grease it up again. After finished tapping, I used my shop vac. to suck out the grease, then use q-tips to finish cleaning. I got all the grease out and used the vac. again. This process took about an hour and on a COLD motor.

 

What size tap do yuo need for the pyro probe?

 

On mine, it's 3/8ths. I drilled the final hole with a 5/16ths drill bit then used a 5/16 tap and worked up to the 3/8ths as I described above. My taps are narrow tipped so I can do that.

 

i would recommend a right angle drill makes it a lot easier?

 

X2!!!!!!!!

 

Thanks guys.

 

whats X2 mean
???????????

 

I think he agrees.

 

I drilled mine using grease on the bit and took it slow. Going through the manifold I didn't get any chips just a fine powder. I did fire up the engine when it got close to penetrating through. I wore welding gloves to protect my hands and goggles to protect my eyes. When I tapped the hole I used lots of grease and cleaned it out after every turn or so. I have since had no problems and my boost has reached and held 30 psi when pulling long grades.

 

I've was wondering how much boost these trucks would make I haven't pulled anything heavy yet but lookng forward to doing it .

 

I've was wondering how much boost these trucks would make I haven't pulled anything heavy yet but lookng forward to doing it .

 

mine is an stk 06' and i can hit 28psi easy

 

I have some mods.and I've held 40lbs. of boost steady for about 3/4-1 mile going 50 mph in a 45mph going up a 7-10% grade towing my trailer/car (app.7000#'s) with 1230 egt's.