jp4 in saxo vts inlet manifold drilling

[craggy]

Hi,

The kids were in bed and the wife was doing the ironing tonight so I decided this was the time to drill, tap and fit my j4 inlet manifold to my jp4 head.

everything went well to some extent, it fits like a glove, all 9 bolts have got a hold an its nipped up, however the front, top, left hole (as you look at it whilst drilling) I went to deep and hit a void. I thread locked the bolt and hovered out the swarf, but to save me a future job of finding out the hard way does this head need scrapping or is it ok?

Im not really sure what chamber I have exposed with the drill?
ta

[blackie_2k5]

Probably a water way/jacket or oil gallery.

Get a pic if poss.. More then likely fucked.. But post a pic.. Stick something in the hole as far as it'll go, then measure how deep the hole is

[monka]

I dont get why people drill and tap the head, when you really dont need to, cutting a a couple of penny shaped parts out of the standard gti/vts manifold is all you need to do

[gazza808]

How deep have you drilled it?
Could you get a very short grub screw, smash some hydraulic hitemp thread sealant or or donkey tape on it and bottom it out in the bottom of the hole?
Or is it a full through hole?

[saxova]

I dont get why people drill and tap the head, when you really dont need to, cutting a a couple of penny shaped parts out of the standard gti/vts manifold is all you need to do

I don't even have any holes drilled in!

Just some weird brackets to clamp the inlet on when the holes aren't lined up. Like they had on the actual C2 VTS :y:

[craigbarley]

I dont get why people drill and tap the head, when you really dont need to, cutting a a couple of penny shaped parts out of the standard gti/vts manifold is all you need to do

Monca that's cutting these penny shaped parts out do?

[craggy]

http://farm8.staticflickr.com/7447/8717251974_e59f70b63f_z.jpg (http://www.flickr.com/photos/95426706@N07/8717251974/)

[craggy]

I ended up drilling and tapping because I had pdf'd two guides and both had it down as drilling. bloody annoying that the last one I did I went a bit far in (didn't read the guide properly!), oh well live and learn.

I didn't realise you could do it any other way. I have basically covered that threaded bar that is in there in instant gasket and tightened it up as much as I could. will just have to try getting a nut on it now (its the top left hole which I think should normally be a bolt) if it don't work i'll have to throw it in the bin and start again with the notching method or learn to drill properly

[monka]

Monca that's cutting these penny shaped parts out do?

allows you to fit the standard gti/vts inlet manifold using that standard jp4 inlet bracketry, just cutting little bits out of the webbing on the actual manifold, not the head, so that you just use standard brackets and dont need to fuck about drilling holes and shit, and ending up doing as described in op

[craggy]

I still cant work out what the void is, im hoping its as per what blackie has suggested, I have gone right through by the way, cant really get a better pic unless I dismantle the lot. think I might have to just start the thing and see if it works, pain in the arse if it doesn't its a 30k 2007 jp4 lol a little hobby of mine gone wrong it seems

[gazza808]

Tbh if you stick a stud in it with some sealant etc on it chances are it'll be fine, just keep an eye on it.

[adzvtr]

just be carefull not to block or restrict the flow with the stud if it is a water or oil way that could cause you some issues..

[ThrushMotorsport]

You could have hit something, however, maby next time its practice to measure it, then wrap a bit of tape round the drill bit to tell you where to stop ;)

[adamskiTNR]

I'd get a new head. Not very expensive and it sounds like a water jacket to me. you'd have to be pretty unlucky to hit an oil way. If not make sure to flush both systems through before assembly. The swarf will still be lurking in there.

[axsaxoman]

If stud is good fit --then with sealer --(thread lock ) it will be fine
you only need to drill in approx 18mm as the studs do not have thread that long ,but you need a little extra depth for the tap

[craggy]

If stud is good fit --then with sealer --(thread lock ) it will be fine
you only need to drill in approx 18mm as the studs do not have thread that long ,but you need a little extra depth for the tap

Thanks all, with this new found confidence that it should not have caused mayhem in my cylinder head I am going to take the manifold off, remove the stud and my makeshift thread locker, and invest in the best thread lock product I can find and get the thing bolted together properly, also perform a flush (however that is performed lol)

I have a complete j4 engine that i have the possibility of taking the cams out of to put in this JP4 but as I know nothing about cam timing I was going to leave them out and be happy just to get the engine to "work" in a saxo. I wonder if doing this swap will give me a view of my hole and any swarf, might push me to do the swap which brings more risk I didnt want but hey ho.

FYI, im no mechanic, just happen to have a saxo that I wanted to take apart and rejuvinate, as its been stood over a year.