Author Topic: 1.6 IDI Waterjacket Improvement (Read 17640 times)

theman53 · « **Reply #30 on:** May 07, 2008, 10:51:51 pm »

Maybe another material and made from scratch? Or call Fel pro and see what they would do for us? I used to work in an injection molding place and we used beryllium copper for the molds. The main reason was because it didn't really expand or expand as much as anything else would when such high heat and presure were applied...I wonder if someone makes a gasket or could out of that. Once again it is just a thought

fatmobile · « **Reply #31 on:** May 10, 2008, 01:38:40 am »

Quote

have my 1.9 HG on hand. I was planning on using it but was thinking of doing the block mod. Any one have the pictures from the front of this post saved?

If you have a 1.9 headgasket,... I think it has the holes in it..
Down in the "V" between the cylinders, on each side of center....
6 holes?

53 willys · « **Reply #32 on:** November 16, 2008, 10:50:35 pm »

What size drill bit are you guys using??? I'm at work and cant see the pics...is 1/8" drill big enough???

Smokey Eddy · « **Reply #33 on:** November 16, 2008, 11:01:36 pm »

Has anyone made a jig for driling these while the block is still in the car? I want to make one but if someone has already done this is would be a great template. Please let me know!

53 willys · « **Reply #34 on:** November 16, 2008, 11:47:03 pm »

Quote from: "Smokey Eddy"

Has anyone made a jig for driling these while the block is still in the car? I want to make one but if someone has already done this is would be a great template. Please let me know!

the jig is the 1.9 AAz headgasket....if your doing this mod you will already have the jig! :wink:

Smokey Eddy · « **Reply #35 on:** November 16, 2008, 11:50:58 pm »

by jig i mean a ways of drilling the block without using a drill press or drilling by hand.

I mean a jig that adheres to the block and you stick your drill into like guides and just push down while drilling and the guides hold you true and straight

or since its just half an inch do most people just say f*** it and drill by hand "yeah that's straight enough..." *wrrrrrrrrrr* crack. "whoops. drilled into the cylinder wall... oh well it's not important."

I guess i'm really asking how big is the water jacket. If you start at the right point do you have to be extremely deficient to miss it drilling by hand?

fatmobile · « **Reply #36 on:** November 17, 2008, 12:51:08 am »

You should be able to slide something into the waterjacket, next to where you intend to drill and feel what's behind where you are drilling.

I don't think the hole needs to be real straight,... just needs to line up with the hole in the gasket.

monomer · « **Reply #37 on:** November 17, 2008, 05:51:09 pm »

Quote from: "Smokey Eddy"

by jig i mean a ways of drilling the block without using a drill press or drilling by hand.

I mean a jig that adheres to the block and you stick your drill into like guides and just push down while drilling and the guides hold you true and straight

or since its just half an inch do most people just say f*** it and drill by hand "yeah that's straight enough..." *wrrrrrrrrrr* crack. "whoops. drilled into the cylinder wall... oh well it's not important."

I guess i'm really asking how big is the water jacket. If you start at the right point do you have to be extremely deficient to miss it drilling by hand?

Center punch and an airdrill is all you need.

if your worried about being perpendicular; use a ve-block to make sure the drill is straight.

A drill bushing setup would be overkill; But I could make some up after I get my 1.9 head here.

(<---Tool/Die maker; specializing in composite hand-apply drill fixtures for Lockheed Martin)

Smokey Eddy · « **Reply #38 on:** November 17, 2008, 06:41:11 pm »

Quote from: "monomer"

use a ve-block to make sure the drill is straight.

Ahhh! excellent. I think my old high school shop has one. Maybe i can use it!!!
thanks for the tip. Exactly what i asked for!!!
thanks fatmobile too. I appreciate all advice!!!
Cheers guys.

jtanguay · « **Reply #39 on:** November 17, 2008, 07:15:01 pm »

here's a tip - put plastic over the block and put tape over where you're drilling... this will help keep any bits from getting into the bores :wink:

or maybe someone else has a better idea

monomer · « **Reply #40 on:** November 17, 2008, 07:38:03 pm »

Quote from: "Smokey Eddy"

Quote from: "monomer"

use a ve-block to make sure the drill is straight.

Ahhh! excellent. I think my old high school shop has one. Maybe i can use it!!!
thanks for the tip. Exactly what i asked for!!!
thanks fatmobile too. I appreciate all advice!!!
Cheers guys.

any tool supply shop will sell them.

a simple block should be no more than $20. Harbor freight may even have them.

A circular level on the back of the drill will also work (assuming the head is sitting level)

53 willys · « **Reply #41 on:** November 17, 2008, 10:37:32 pm »

I did my head last night...1/8" drill is what I used I then deburred the holes.

I used green painters tape and taped everything just like mentioned in this thread....it went SUPER EASY with my 18volt dewalt drill...I'm gonna do the block tomorrow..I'm gonna do it the same way as well..hand drill with the cordless dewalt..
wish me luck!!..lol

zukgod1 · « **Reply #42 on:** November 18, 2008, 10:48:52 am »

Quote from: "53 willys"

I did my head last night...1/8" drill is what I used I then deburred the holes.

I used green painters tape and taped everything just like mentioned in this thread....it went SUPER EASY with my 18volt dewalt drill...I'm gonna do the block tomorrow..I'm gonna do it the same way as well..hand drill with the cordless dewalt..
wish me luck!!..lol

Grease the drill bit to keep metal in the block to a min..

lord_verminaard · « **Reply #43 on:** November 19, 2008, 10:33:44 am »

Wait, so the head needs drilled too?

53 willys · « **Reply #44 on:** November 19, 2008, 10:36:35 am »

Quote from: "lord_verminaard"

Wait, so the head needs drilled too?

yes for the 6 holes around the water jacket yes you will need to drill holes in the head and block.