tbspacer 010.jpg 22 hits | 32.11 KB | Posted: 8/5/08 So I got carried away and finished with no more pictures. I filed and ground and sanded the sides until they were smooth and square. Then I marked, center punched and drilled the four mounting holes. Last, I lightly sanded all the surfaces to remove ...
tbspacer 009.jpg 20 hits | 73.56 KB | Posted: 8/5/08 The hole is cut and the sides trimmed to almost the finnished dimension.
tbspacer 008.jpg 15 hits | 68.76 KB | Posted: 8/5/08 This takes a long time. You need a sharp hole saw and lots of time and oil. I found it worked best to pulse the pressure on the saw and bring it up often to clear the chips. Still it took about an hour and that doesn't include time to let the drill p...
tbspacer 007.jpg 18 hits | 85.49 KB | Posted: 8/5/08 Once the hole is started switch the wood to the bottom.
tbspacer 006.jpg 19 hits | 80.81 KB | Posted: 8/5/08 All set up to bore out the center hole. everything is clamped down so it won't move around. See how the wood supports the hole saw.
tbspacer 005.jpg 18 hits | 71.13 KB | Posted: 8/5/08 First use the hole saw to cut a hole in a piece of hard wood so that the hole saw won't wander around when it begins to cut into the aluminum.
tbspacer 004.jpg 14 hits | 87.19 KB | Posted: 8/5/08 Find the center of the hole, deeply center punch and drill the 1/4" pilot hole.
tbspacer 003.jpg 17 hits | 68.7 KB | Posted: 8/5/08 Using the hole saw to get a better idea of where the center of the hole is. It's surprisingly hard to find the center of a circle.
tbspacer 002.jpg 18 hits | 74.89 KB | Posted: 8/5/08 This time the flash worked so you can see the pile of stuff the 1x3.5x12 6061 bar is sitting on. If you work metal your work bench probably looks like this most of the time. Clean benchs are not a good sign.
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tbspacer 010.jpg 22 hits | 32.11 KB | Posted: 8/5/08 So I got carried away and finished with no more pictures. I filed and ground and sanded the sides until they were smooth and square. Then I marked, center punched and drilled the four mounting holes. Last, I lightly sanded all the surfaces to remove ...
tbspacer 009.jpg 20 hits | 73.56 KB | Posted: 8/5/08 The hole is cut and the sides trimmed to almost the finnished dimension.
tbspacer 006.jpg 19 hits | 80.81 KB | Posted: 8/5/08 All set up to bore out the center hole. everything is clamped down so it won't move around. See how the wood supports the hole saw.
tbspacer 002.jpg 18 hits | 74.89 KB | Posted: 8/5/08 This time the flash worked so you can see the pile of stuff the 1x3.5x12 6061 bar is sitting on. If you work metal your work bench probably looks like this most of the time. Clean benchs are not a good sign.
tbspacer 005.jpg 18 hits | 71.13 KB | Posted: 8/5/08 First use the hole saw to cut a hole in a piece of hard wood so that the hole saw won't wander around when it begins to cut into the aluminum.
tbspacer 007.jpg 18 hits | 85.49 KB | Posted: 8/5/08 Once the hole is started switch the wood to the bottom.
tbspacer 003.jpg 17 hits | 68.7 KB | Posted: 8/5/08 Using the hole saw to get a better idea of where the center of the hole is. It's surprisingly hard to find the center of a circle.
tbspacer 001.jpg 15 hits | 50.06 KB | Posted: 8/5/08 Ok, I decided to make a throttle body spacer for my jeep. I've heard they aren't worth much on the 4.0 but I have to think that anything would help that crappy log manifold. In this pic I'm using a new gasket to lay out the cut lines and the hole.
tbspacer 008.jpg 15 hits | 68.76 KB | Posted: 8/5/08 This takes a long time. You need a sharp hole saw and lots of time and oil. I found it worked best to pulse the pressure on the saw and bring it up often to clear the chips. Still it took about an hour and that doesn't include time to let the drill p...
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