[Damo]

I've got a little job to do and need some guidance on what tool to use.

The workpiece is a cast alumiunium inlet manifold and I need to put some ~10mm holes in it so I can fit some injector bungs. Holding it shouldn't be an issue, I can make up a jig for that. I just need to know what the appropriate tool is.

[ball]

A drill

[DMAC]

ball wrote:

A drill

Yep that'll do it.

[brendan]

a drill and maybe a tap?

[Damo]

Oops, I didn't mention that the work is on a 45 degree angle.

[appsie]

is this on the mill?

[brendan]

use a mill with a tilting head or if posible in a milling vice that can tilt?

[Damo]

Yes, in a mill.

I can set the manifold up on a jig to get the 45, I have that part sorted.

What tool do I use? Surely a normal drill will just run away across the surface instead of cutting into it.

End mill?

[sr20zook]

centre punch, small pilot hole first

[brendan]

sr20zook wrote:

centre punch, small pilot hole first

thats what i would do. maybe even drilla small pilot hole with a hand drill first?

[ball]

Damo wrote:

Yes, in a mill.

I can set the manifold up on a jig to get the 45, I have that part sorted.

What tool do I use? Surely a normal drill will just run away across the surface instead of cutting into it.

End mill?

An standard end mill won't work. They don't cut in the centre.

A normal centre and small pilot hole is not usually successful either as the drill will still wander.

I would use a ball nose end mill to get a hole started then just punch a regular drill through it to get the size you need.

[Damo]

ball wrote:

Damo wrote:

Yes, in a mill.

I can set the manifold up on a jig to get the 45, I have that part sorted.

What tool do I use? Surely a normal drill will just run away across the surface instead of cutting into it.

End mill?

An standard end mill won't work. They don't cut in the centre.

A normal centre and small pilot hole is not usually successful either as the drill will still wander.

I would use a ball nose end mill to get a hole started then just punch a regular drill through it to get the size you need.

OK, that makes sense.

Faark... more tools

[ball]

Yep and make sure you are sitting down when you get a price for them too.

[appsie]

nothing wrong with more tools.

At tafe we had to drill holes at 45 through blocks etc just on the drill press.Just using a centre drill to start it off got it pretty close to spot on and didnt wander.Set up in a vee block and vice

but as ball said go a ball nose end mill to stop the wandering problem

[SuziBlu]

He who dies owning the most tools, wins.

[hutch]

SuziBlu wrote:

He who dies owning the most tools, wins.

Nup... cause those who die last take all the others tools and adds em to their collection then make a tomb from them and nestles in for a comfy ride to heaven!

[brendan]

SuziBlu wrote:

He who dies owning the most tools, wins.

haha thats my plan

[Damo]

Just had a brain wave would the ball end rotary burr from my die grinder work? It's to suit aluminium.

[ball]

You won't be able to spin it fast enough in the mill to get a decent cut

[Damo]

OK grave dig time. I've finally got some bits and pieces for my mill but I didn't stretch to ball nose end mills The job is a standard Sierra 1.3 inlet manifold that is being machined to accept fuel injector bungs. The bungs have been purchased seperately and it's intended that they be epoxied in place, they require a 14mm hole.

When set up in the jig I made the manifold is at 45 degrees, and the cutter is mounted vertically (vertical mill), so like Ball mentioned I need to start it somehow. I do have a 2.5mm centre drill, i'm thinking of giving that a go. Otherwise i'll get a cheap HSS ball nose end mill (it's only cast aluminium i'm working on) and go that way.

UNLESS anyone has any other ideas?

[ball]

Can you mill a small flat where you want the holes to go ?

A drill will still try and wander if the surface is on an angle even if you have a centre in it.

[Damo]

ball wrote:

Can you mill a small flat where you want the holes to go ?

A drill will still try and wander if the surface is on an angle even if you have a centre in it.

You mean feeding an end mill in from the side? Bringing it down vertically wont work, even just to make a flat like that?

I might be able to do that, i'll have to have another look at it to be sure. I am confident that would work for the outside cylinders but for the inside ones there might be stuff in the way.

[ball]

Yep, feeding in from the side.

If that doesn't work then a slot drill will plunge cut, an endmill won't

[gman]

Just a thought< how different is a inlet manifold off a 16 valve 1.6 engine? they have an injector on each intake tube don't they? I guess how is it bolted to the head?
maybe there are small hurdles using a different manifold ?

[Damo]

gman wrote:

Just a thought< how different is a inlet manifold off a 16 valve 1.6 engine? they have an injector on each intake tube don't they? I guess how is it bolted to the head?
maybe there are small hurdles using a different manifold ?

Yes the 16v manifold has an injector for each runner but, as you suspect, the mounting flanges are completely different.

If I had a 16v manifold I might give it a go, but the idea behind doing it this way is that the standard 8v manifolds are plentiful, eg. cheap.

Well that and it gives me an excuse to play with my mill

[royce]

whats wrong with just going straight in square? the boss should cover the bigger hole needed?

[shep]

hay damo just post it to ball, he likes working on suzuki stuff.

[Damo]

royce wrote:

whats wrong with just going straight in square? the boss should cover the bigger hole needed?

How do you mean? Fit the boss at 90 degrees to the airflow? I was trying to avoid that.

shep wrote:

hay damo just post it to ball, he likes working on suzuki stuff.

Yeah now that you've left he probably has some spare time on his hands

[royce]

does the boss you have not it on top of the manifold and just the injector pokes through the hole?

[Damo]

royce wrote:

does the boss you have not it on top of the manifold and just the injector pokes through the hole?

Yep that's pretty much it.

I was going to take some pics last night but have stopped using my phone (E71) because the pics come out so crap. I'll take the digi cam out to the shed tonight and take some snaps, it should make it a little clearer what i'm trying to do.