Let the cutting begin......

[machoneman]

So what does Heo win...a pair of LeMans valve covers? LOL!

[65er]

So what does Heo win...a pair of LeMans valve covers? LOL!

bag-o-chips, lol

Cool project, I'll be interested in seeing it develop too.

[jayb]

I am making a hell of a lot of chips. This be one side. Its gunna take me a day to clean up before the next operation!!

Reminds me of a quote from Lil' John Buttera, published in Hot Rod many years ago.

HR:  "How do you machine a billet aluminum side mirror?"
Buttera:  "You just start with a big chunk of aluminum and machine away everything that doesn't look like a mirror!"

[Heo]

So what does Heo win...a pair of LeMans valve covers? LOL!

An all inclusive vacation in Australia would be nice

[66FAIRLANE]

Anyone else think these holes might be a bit small to feed an angry FE? That's a 600 gasket by the way. Holes at 27/32.



Good thing I ordered me one of these...

http://www.ebay.com.au/itm/New-MT3-M12-Morse-taper-50MM-Boring-head-9pcs-12mm-boring-carbide-tips-box-/161516680832?pt=LH_DefaultDomain_15&hash=item259b24f680

[66FAIRLANE]

It was a humid one here today. 8pm it was 28C and 70% humidity in my shed and the only way I had to cut this in half was a hacksaw. I was saturated with sweat. I now have the holes at 1-1/16. Not the prettiest but the mill will fix that and the cheap Chinese boring head has arrived.

[66FAIRLANE]

A little more progress last night. Tidied up my sublime hacksawing and took the two TB's down to the same height.





Then spotted through the base plates and drilled and tapped to accept.



Base plate bolted on. Have to pick up the rough throat holes and whack em through the base plate. I am at 1-1/16 at the moment. I have a 1-1/4 drill but I can't hold it as it is MT4. I might turn it down to MT3 and if that works from there I can use the boring head and sneak up on 1-9/16.

[66FAIRLANE]

Well, this is going to require something I don't have much of (and can't buy on ebay), patience!

I need to take out 1/2" with the boring head! Ah well....suppose I have the time. Did one hole last night and it came up pretty good. Now it is set up I can just do one whenever I feel like it.

Didn't really bother about exact hole positions when I roughed out the holes. Its a bit more critical now.

Clocking it up square


Boring head about to go in


One hole done

[66FAIRLANE]

Spreadbore EFI anyone?


Didn't think so


Only done one at this stage and will probably concentrate on it until finished. Next thing is disassemble and rough cut the corners off of the top and clock up in a 4 jaw chuck (hope it fits!) and turn the air cleaner seat. Then bore holes in base plate for throttle shafts.

[66FAIRLANE]

Chucked up in the 4 jaw and starting to look like a throttle body.

[ToddK]

Probably be easier to buy an off-the-shelf unit, but nowhere near as much fun.

Definitely watching to see how this turns out.

[66FAIRLANE]

Probably be easier to buy an off-the-shelf unit, but nowhere near as much fun.

Definitely watching to see how this turns out.

Definitely, but it gets me out of the house and having a quiet tipple in the shed. Just always wanted to make one for some reason. Now I'm making two.

[cobracammer]

That's awesome!  I get such a rise out of people taking a chunk of metal and machining out a custom piece.  Keep on Keeping on!

[66FAIRLANE]

A little more progress.
Decided to put a 'lead in' on the throats and settled at 10 degrees. Had to clock up each one in my 4 jaw chuck to get centre and then slowly does it as I was only holding with 2 jaws. The body was offset so far that one of the jaws would hit another before contacting the job.

Clocking up


Slowly does it


Two done for comparison


All 4 done


Now to work out how to bore a long straight hole for the throttle shafts. Hmmmm.............

[Heo]

Nice job.There is special drills for long holes.Gun drills
but.....they dont work there since you got the throtle
bore there...If you bore undersize and index carefully
and use a loong reamer with the right size