Take your time, Try not to tap to fast (AKA back it out every half turn or so) Dont use Grease but use some PB blaster on your tap, That will also make things easier.
When drilling your manifold, use a fine point punch to get a pilot started. Then use your 23/64 (if your using a 1/8NPT Therm. Coup.), Drill slow, Dont try to force to hard on it!
Try to use a high quality bit , I use alot of Dewalt bits that have a nice point on the end for starting! As you get closer to punching through take it very slow to avoid binding your bit. Make sure your hole is straight by keeping the drill as straight as possible! Also use some PB on the bit as you drill!
Once drilled you've got a few options, Start it with the hole open to blow shavings out... Now before anyone disagrees lets keep in mind that 90% of the drill shavings exited via the bit. Your tap dust is so fine that it really wont cause any problems!
If your worried, Just take a shop vac and put over the hole!
Remember that this is NOT a hard process, Just relax and take your time, Once you get the feeling of the tap , you'll be much better!
thanks fish fry i really appreciate you walking me through it. Im going to go get my bits and tap tonight and maybe have at it tommarow night or so. With the stock trans and 125k miles would it be ok to turn up my pump and slide my plate forward for alittle extra power?
BBram, where is chelsea compared to Clarkston? I am about 5 minutes north of great lakes crossing mall if that helps any. The guys from coaltrain where supposed to come up this weeeknd and do timing and bring me a 5in turbo back, but i havent heard from them yet. Give me a call at 248-342-2865 if thats easier.
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