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BB Exhaust jig 3D printed

shepherm

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So one of my exhaust studs on my Charger was broken and didn't have much luck with Kroil, welding, or left hand bits. So next I want to drill it out to see if I could re-tap the hole. I knew I wanted some type of jig to hold the bit straight and centered. Looking back I should have start with one of these before trying the left hand bit.

So I designed and printed a few different ones with the polit holes sized for a few end mills I hand. I started with a small end mill and worked up to a 5/16. Worked much better than I expected and centered the hole perfectly. If I was doing this often I would make from metal and a mill, but they were handy for a one time use tool.

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Did it work? is the head on the engine in the car or off on the bench? got pics of that?
 
Did it work? is the head on the engine in the car or off on the bench? got pics of that?

I believe it worked pretty good. I haven't bolted the exhaust manifold back on yet but I tested the threads with a bolt and washers and torqued them down. I don't have any pictures of me using it but here are a couple I just took just now. The head was still in the car, and that's why I wanted something to help drill it straight.

I used 3 different sized end mills, starting with the smallest and working up. As you can see there wasn't much clearance, even when I jack the motor up. That's why the end mills work better than drill bits. They are shorter and stiff, allowing for more room and less deflecting.

To use it, I just started with the smaller 4 flute end mill and pecked, pulled it out to clean the chips and repeat. Then stepped up to the next size until I got to the 5/16.

Note: I couldn't use the other studs in the head because the tolerances were too tight and the jig would not slide over them, so that's why I used the bolts. With the bolts it it flush with the head, not like it is in the picture.

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Cheater! :lol:. You need to perfect it and get a patent on it. Get that baby into production for B, A and Hemi. Probably other engines too. Lots of broken studs in heads out there to save.
 
Cheater! :lol:. You need to perfect it and get a patent on it. Get that baby into production for B, A and Hemi. Probably other engines too. Lots of broken studs in heads out there to save.

There is one for the hemi gen 3 already being sold
 
If you end up making units to cover the A,B and Hemi[ 2nd gen], I'd be interested in adding those to my Mopar tool stash.
 
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