I'm building a Schedule 10 1.5" SS header and need to cut a hole in my collector for the wastegate. How do you go about doing this?

I would use a plasma cutter, but I dont want all the crap it leaves behind to clean up. My other idea is to use a hole saw on my drill press.

Regards,
Justin

 

I just use a Drill Press and Hole saw, make sure that the press is on the slowest speed setting.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by TurboElements.com &raquo;</TD></TR><TR><TD CLASS="quote">I just use a Drill Press and Hole saw, make sure that the press is on the slowest speed setting.</TD></TR></TABLE>

or if you have no patience like me you can cut it fast but go through a hole saw every cut

 

Jesse I hear you on that, I used to be that way but after spending $$$$$ I got some patience.

It also helps if you only tack the collectors and cut the hole and then do the finish weld.

 

dont use a plasma cutter! i made that mistake once when i was out of hole saws trying to build a manifold at 3am.

ever notice you never have what you need at 3am when nothing is open, and usually thats when your in the biggest rush.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Turbo-charged &raquo;</TD></TR><TR><TD CLASS="quote">dont use a plasma cutter! i made that mistake once when i was out of hole saws trying to build a manifold at 3am.

ever notice you never have what you need at 3am when nothing is open, and usually thats when your in the biggest rush.</TD></TR></TABLE>

Oh dear lord all the time.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by TurboElements.com &raquo;</TD></TR><TR><TD CLASS="quote">

It also helps if you only tack the collectors and cut the hole and then do the finish weld.</TD></TR></TABLE>

Found this out the hard way...lol. Thanks again man.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Turbo-charged &raquo;</TD></TR><TR><TD CLASS="quote">
ever notice you never have what you need at 3am when nothing is open, and usually thats when your in the biggest rush.</TD></TR></TABLE>


i ran out of welding wire at 4am and the car had to be done @ 8am (full exhaust system). i was standing outside harbor-freight @ 6am to find out they didnt open till 8 then i had to go to home depot which happened to open at 6. i hate running out of supplies or breaking something during a late night project. since then, i learned to over stock on the minor things (flanges, gaskets, bolts, welding wire/sticks and most importantly, chop saw blades)

 

my question is: where do you get your whole saws at and how much? when i was doing my hole for the wastegate, i bought a "kit" from harbor freight to find out it was bi-metal/wood and ate the teeth up (drill press wasnt on lowest speed though). i ended up using a drill, drilled a bunch of little holes and used an air hammer to punch the center out. then i used porting bit to clean it up.

 

home depot sells bi-metal holesaws. they are rigid brand. like $9 each. 1 1/2".

at my old job we used lenox 1 1/8 hole saws to put holes in 1/16-1/8" stainless exhaust hoods and i could get 30+ holes out of one without using any cutting oil. not sure if its a better brand or the actual thickness material that affect the lifespan.

 

The lenox seem to last longer than the rigid saws...

 

i guess im gonna have to pick up some lenox ones then.

 

you could use a T inplace of the one runner of the collector.then the hole is already there for you..

 

have fun making a collector cut on a tee.

 

What cutting oil do you guys like to use?

Justin

 

I just hit that **** raw.

 

No lube?

 

raw dog it

 

I'd hate to see how some of you would notch roll cages if you built one, you'd have to have 10 holes saws around just to be able to do one cage.

I cut all of the holes in thicker metal (cage tubing, thicker walled manifolds, etc...) with a dill and a hole saw made for cutting the same type of metal. Lube? if you have cutting tool oil use it or reg WD or similar work good as well. Go slow and take your time if you want to save your hole saws.

There are other ways to cut the hole but, the hole saw is probably the easiest way to do it without the fear of colladeral damage to what your working on or stuff around it.

If you have a 4 axis cnc laying around, try it out once, they cut nice holes

 

everytime i try to hit that **** raw, it takes like 10 ******* minutes to make one cut. I dont know if its a good thing or bad thing as opposed to a quicky.

 

what kind of hole saw are you using. using a drill press or a hand drill? we use rigid hole saws on a rigid drill press on the slowest speed and it takes about 60 second to do a wastegate hole with no lube. lasts for 4-5 holes that way.

 

for some reason i was thinking about making a collector. ooops

 

Hole saw

Or

Plasma with a shitload of Anti-Spatter sprayed inside. Not chunks or stuff let behind when your done.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by JK_Motorsports &raquo;</TD></TR><TR><TD CLASS="quote">Hole saw

Or

Plasma with a shitload of Anti-Spatter sprayed inside. Not chunks or stuff let behind when your done.</TD></TR></TABLE>

anti spatter doesnt work all that well, for me anyways. plus its bad for you to inhale.

 

I use dewalt bi-metal hole saws. They are about $14 each but I still have my original one and it has been through 8 sch 10 collectors. It takes about a minute or less to cut through. I just use oil.