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!

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 .

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

Rich

laser cut? plasma? water jet?

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)

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.

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....

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.

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

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.