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**JohnStranahan** · 03-18-2008, 08:43 PM

Work proceeds on 3/18/2008
The nephew is at hand and work proceeds. We made an 8 mm pilot from .5 inch drill rod. Drilled it .125 then .128 for a light fit of a 1.25 inch transfer punch. We used this and the gasket template to center punch the mounting holes. These were then center punched with a larger punch. The photo shows the pilot and center punch laying on the ABS plastic flange. The wiggler is installed in the milling machine (or large drill press) to drill the holes out for smooth metal inserts.

The next step is drilling 2 inch giant angled holes in the flange. Picture to come this week.

We made an 8mm pilot for a .125 in center punch. We used this to center punch the manifold flange attachment bolts. Use a wiggler to align the mill or drill head to the punch mark.

john

03-18-2008, 08:43 PM	#115 (permalink)
JohnStranahan Junior Member Join Date: Dec 2004 Posts: 98	Re: Suzuki GSXR 750 quad Throttle Body Install on 2.3 L Duratec Work proceeds on 3/18/2008 The nephew is at hand and work proceeds. We made an 8 mm pilot from .5 inch drill rod. Drilled it .125 then .128 for a light fit of a 1.25 inch transfer punch. We used this and the gasket template to center punch the mounting holes. These were then center punched with a larger punch. The photo shows the pilot and center punch laying on the ABS plastic flange. The wiggler is installed in the milling machine (or large drill press) to drill the holes out for smooth metal inserts. The next step is drilling 2 inch giant angled holes in the flange. Picture to come this week. We made an 8mm pilot for a .125 in center punch. We used this to center punch the manifold flange attachment bolts. Use a wiggler to align the mill or drill head to the punch mark. john