Ive done this several times, and all times ive done it a very ghetto way. Since I usually make the wastegate tube come out of the collector, I need to make a hold in it perpendicular to flow(relatively) How do you make this hole? I typically use a grinding wheel and grind a hole...then use a carbide bit to clean it up. Using a hole saw never seemed to work since I could never get the collector to "stay" in the vice.

 

not sure on what you may have access to interms of tools but usually a tube vise, which has opposing V jaws or just a V block can hold your work peice so you wont get chatter and other dangerous things going on. a good bimetal hole saw well work as long as your going slow (both rpm and feed), using coolant, and its in a larger drill press or bridge port of some kind. there should be near zero clean up work when its fixtured properly, the one peice is a straight bore, the other notched to the o.d. of its mate.

 

Weld the collector together and use a mill if you have access to one.

 

use a nice hole saw for metal such as a Lenox, use a nice press that you can turn the speed down on. Most people run 3X the drill speed they should be. Lastly, keep the saw cool. Some use cutting oil, I actually have a squirt bottle just filled with water, spray the saw when youre cutting the hole. My technique is when I see steam then the saw is too hot so I up the spraying. That is a good method to throttle how much you spray. Done properly a hole for a WG in sch40 pipe should take around 5 min to cut tops and I usually get 3-4 manifolds per saw.

HTH

-bill

 

thanks guys!

 

It's very hard to do without a good drill press and clamps.

I just took it to a machine shop, they did it for the price of a hole saw!

 

how much did they charge you? Im just curious

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ~RTErnie~ &raquo;</TD></TR><TR><TD CLASS="quote">how much did they charge you? Im just curious</TD></TR></TABLE>

$20-$30? (CDN).. I had a few other things done at the time so I can't give you an exact price.. they can clamp it down and mill a nice clean hole in it in 20-30min tops.

I forget to mention that i ruined hole saw I had laying around before I took it to a machine shop.. If i had a full size drill press and good clamps/vice I'm sure I would have had better luck - but stainless (sch 40!!) is very hard on any cutting tools unless they are top knotch.

 

yeah...not to mention the time it takes...its better to let someone better equipped to deal with it than to have me spend 3 hours hacking away at it lol.

 

what kind of hole saw are you using? The one i have i can cut sch10 in about 5mins with a cordless drill. Only reason it takes 5mins is becasuse i stop and spray lube on it. wont a plasma cutter work?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by 88_DX &raquo;</TD></TR><TR><TD CLASS="quote">what kind of hole saw are you using? The one i have i can cut sch10 in about 5mins with a cordless drill. Only reason it takes 5mins is becasuse i stop and spray lube on it. wont a plasma cutter work? </TD></TR></TABLE>

plasma = dirty. it sprays **** all over the inside of the collector. looks like crap afterwards.

 

Lenox hole saws Go through them like water when working with stainless, but they still work good.

 

im suprised to hearof people having problems cutting holes in collectors. im lucky to have a decenly sized drill press to my acces, this is what i use, along with a hole saw bought from home depot(1 5/8) i think is the size we use. i had a friend hold the manifold on the work area of the drill press, and i man the lever to lower the bit. it took all of 5 minutes to cut that bish.