Zach Zupancic

Zach Zupancic

Senior Designer, SolidWorks addict, AutoCAD zealot, Cyclist, Shade Tree Mechanic, & moderately tall. 

Let's hope this works: part 2

Yesterday I finished manhandling my head and turbo to get everything to bolt up together with the least chance of leaking with the hand that I was dealt.

 To fix the bolt that was broken off in the head I tried reverse drill bits, titanium drill bits, and finally ended up falling in love with cobalt bits. I figured I’d tackle the easier of the two problems first, the turbo. The 15g had the bottom two studs broken off, and there was no way that I was going to try to easy-out them, so I starting drilling into it. The first pilot bit, standard high speed, broke off; the second bit, titanium, broke off; finally the third pilot bit, cobalt, went through it like butter. I was able to center one of the bits perfectly on one of the bolts, but on the other I wasn’t as lucky. So instead of having 4 equally round holes I now have 3 and 1 more like a slot. After that was taken care of and cleaned I moved onto the head.

I tried every pilot bit that I could find and/or buy to get drill into the snapped easy-out but nothing was working. So I called up Josh and asked if I was to drill and tap on either side of the hole would that accomplish sealing the manifold. He said that I was taking a very drastic approach and could not guarantee that it would work, but there is a chance that it might. Seeing as I had no other option I took the chance. Aluminum is super easy to cut through so I went at it slowly. After that was taken care of I tapped into the head with a 1/4-28 bit.

I hope this works

Then I put some bearing grease on the head and mounted up the YoshiFab adapter plate to get an idea of where the two holes were placed. I took out my cobalt bits and started drilling away. I knew that there was really no way that I was going to get the holes perfect on the first pass, so after a few mounting and test fits later I was able to open the holes up enough to clear the bolt.

I hope this works

Put in the bolts and tightened the whole plate down.

I hope this works

This led to another expected issue, bolt head clearance with the manifold.

I hope this works

Marked up the manifold, put it in a vise and started grinding away the worthless material. In the end it looked like this.

I hope this works
I hope this works

Mounted it to the plate, and tightened all of the bolts down. And by the way, does volvo hate the people that work on their cars? Because who in their right mind would make a 4 piece exhaust gasket...

I hope this works
I hope this works

Now my engine is really starting to look like a real one.

I hope this works

Today my only goal is to re-clock the turbo and order the clutch, pressure plate, and pilot bearing.

-‘till next time