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914World.com _ 914World Garage _ SOT: 2-1/8" dia. holes in 0.5" AL manifold plates

Posted by: Gary Mar 11 2006, 08:32 PM

Working on adapting a pair of Ninja 636 throttle bodies... They are on 75.6mm centers. There's a lip on the flange that will accomodate a 2" ID - 2 1/8" OD viton o-ring well. I have a couple 1/2" aluminum plates. Rather than going at them with a 2 1/8" hole saws, I figure the better solution is to see if someone has access to or can recommend a shop with a vertical mill or waterjet cutter.

Thnx!

Posted by: Gary Mar 12 2006, 06:50 PM

Bump...

I know some of you guys do your own fab and machine work. How do you cut holes? Don't make me go at these plates with hole saws .

Posted by: r_towle Mar 12 2006, 09:23 PM

yup, hole saw and some good cutting oil...keep it really cool or the hole saw gums up fast.

Rich

Posted by: Aaron Cox Mar 12 2006, 09:40 PM

laser cut? plasma? water jet?

Posted by: Brian Mifsud Mar 12 2006, 09:46 PM

Depending on how hot you are to finish them, I'll have my Bridgeport set up and running in a couple of months. I'm in San Diego, north county...

Holesaw and lots of cutting oil sounds good to me if you are not looking for high precision (can't see why you'd need it..it's only airflow)

Posted by: Gary Mar 12 2006, 11:12 PM

Thanks Brian - may take you up that. My folks are down in S.D.

Don't need high precision, but would like smooth walled holes. Throttle bodies will be o-ring sealed to the holes I make.

Posted by: Mueller Mar 13 2006, 01:10 PM

I'm still debating whether to use an o-ring or just braze the throttle body to the plate.....my original idea of using the hose with clamp is not going to work as well as I thought it would due to interferance with the mounting hardware....

Posted by: Gary Mar 13 2006, 07:30 PM

Eeuuwww... I would wonder/worry about warpage of the TB's. I was thinking set screws horizonally through the plate: front, back and 2 each side for a total of 6.

Posted by: Mueller Mar 14 2006, 12:09 AM

QUOTE (Gary @ Mar 13 2006, 06:30 PM)
Eeuuwww... I would wonder/worry about warpage of the TB's. I was thinking set screws horizonally through the plate: front, back and 2 each side for a total of 6.

I also have an aluminum solder, it melts at 350° (not to be confused with the stuff sold at the county fair ).....my throttle bodies are completly seperate from each other, more than likely I'll put two of them on a common plate

Posted by: Porcharu Mar 14 2006, 01:52 AM

I would use the 2" hole saw and finish them off with a boring bar in a mill. Or just use the 2-1/8 hole saw and weld them in.
If you were in a pinch you could use a 2-1/8" roto-broach in a drill press - they make really nice holes. I would do it for you free if you bought the bit for me. Problem is they cost about $100 in that size.