tbspacer 001.jpg
517 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.
(Posted in: Throttle body spacer)

tbspacer 002.jpg
498 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.
(Posted in: Throttle body spacer)

tbspacer 003.jpg
555 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.
(Posted in: Throttle body spacer)

tbspacer 004.jpg
454 hits | 87.19 KB | Posted: 8/5/08
Find the center of the hole, deeply center punch and drill the 1/4" pilot hole.
(Posted in: Throttle body spacer)

tbspacer 005.jpg
523 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.
(Posted in: Throttle body spacer)

tbspacer 006.jpg
470 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.
(Posted in: Throttle body spacer)

tbspacer 007.jpg
455 hits | 85.49 KB | Posted: 8/5/08
Once the hole is started switch the wood to the bottom.
(Posted in: Throttle body spacer)

tbspacer 008.jpg
483 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...
(Posted in: Throttle body spacer)

tbspacer 009.jpg
464 hits | 73.56 KB | Posted: 8/5/08
The hole is cut and the sides trimmed to almost the finnished dimension.
(Posted in: Throttle body spacer)

tbspacer 010.jpg
506 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 ...
(Posted in: Throttle body spacer)

102_0335.JPG
489 hits | 63.06 KB | Posted: 12/14/07
(Posted in: Pictures)

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672 hits | 50.28 KB | Posted: 12/14/07
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102_0362.JPG
705 hits | 45.57 KB | Posted: 12/14/07
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20150828_104204.jpg
389 hits | 64.2 KB | Posted: 8/28/15
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IMG_20150828_203359.jpg
158 hits | 52.9 KB | Posted: 8/29/15
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IMG_20150828_235140.jpg
152 hits | 63.41 KB | Posted: 8/29/15
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IMG_20150828_203520.jpg
149 hits | 43.53 KB | Posted: 8/29/15
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IMG_20150828_235140.jpg
189 hits | 63.41 KB | Posted: 8/29/15
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20150808_104348.jpg
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245 hits | 69.76 KB | Posted: 8/29/15
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20150830_134940.jpg
231 hits | 92.09 KB | Posted: 8/30/15
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20150830_180637.jpg
195 hits | 91.71 KB | Posted: 9/1/15
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214 hits | 89.84 KB | Posted: 9/1/15
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20150831_211031.jpg
191 hits | 58.54 KB | Posted: 9/1/15
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20150831_211031.jpg
250 hits | 58.54 KB | Posted: 9/1/15
(Posted in: jeep)

20150831_211031.jpg
202 hits | 58.54 KB | Posted: 9/1/15
(Posted in: jeep)