Tapping Manifold for EGT sensor

[MattSTi]

I just ordered Turboxs' EGT sensor setup (same as the EGT sensor kit for DTEC) for my Tuna Pro. I figured that I might as well get this out of the way when I'm doing the Tuna install, and it's a necessary tuning tool.

I've gotten a pretty good idea of what is involved in the actual tapping of the manifold by reading other threads but I have few questions that I would like to clear up.

1. Is it correct that I only need to remove the drivers side manifold, not the cross over pipe, etc.?
2. Should I replace the manifold gasket, and if so, does anyone have a PN for this gasket. Is this the right one? - http://subydude.com/parts/details.php?603
3. Do I need any tools other than
-Drill
-Vice
-Bit
-Tapping bit
5. At what angle should the EGT sensor be installed?

Thanks a lot, any info would be greatly appreciated.

-matt

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[DISCOPOPE]

Originally Posted by MattSTi

1. Is it correct that I only need to remove the drivers side manifold, not the cross over pipe, etc.?
2. Should I replace the manifold gasket, and if so, does anyone have a PN for this gasket. Is this the right one? - http://subydude.com/parts/details.php?603
3. Do I need any tools other than
-Drill
-Vice
-Bit
-Tapping bit
5. At what angle should the EGT sensor be installed?
-matt

1. correct.
2. remember to replace the manifold to block gasket and the manifold to crosspipe gasket.... it looks like the same as the up pipe but it is not. i got mine from rallysportdirect. talk to ben he can get you the correct ones.
3. grinder, or metal file to get your threads flat on the outside of the manifold. cutting oil, tap handle, some sort of cutting tool to trim your heat shield, safty glases.
4. you dont really have much of a choice. i'd say drill into the casting button as close to 90 deg as possable...

[MattSTi]

Thanks a lot discopope, that was very helpful.

If possible, could you outline the actual tapping process from drilling to threading the hole?
Also, what size drill bit will I need in relation to the Tap?

Thanks again

-matt

[Trevor723]

To start, get something to prick the manifold in the center of the casting dot. Next use some varying sized drill bits to make the hole. I used like 1/8", 1/4", and finally 21/64" which is the size required for a 1/8NPT tap. Now you just need to thread the tap slowly into the hole until it bottoms out. Slowly back out the tap and voila, there's your threaded hole.

[Wombat North]

Originally Posted by Trevor723

To start, get something to prick the manifold in the center of the casting dot. Next use some varying sized drill bits to make the hole. I used like 1/8", 1/4", and finally 21/64" which is the size required for a 1/8NPT tap. Now you just need to thread the tap slowly into the hole until it bottoms out. Slowly back out the tap and voila, there's your threaded hole.

FWIW
Unless TurboXS has done a very recent change the thread you just described now doesn't work with a TurboXS EGT probe. You require a 10mm x 1.25 Tap and use an 11/32 drill.

[Trevor723]

Ah sorry. Should have mentioned that I used Defi probe.

[Pirana]

any pics...

[Pirana]

anyone info

[Trevor723]

Very nice post!

[MattSTi]

AWESOME! Thanks a lot man, that helps so much.

-matt

[Uncle Scotty]

....do not 'bottom' the tap.....tap just deep enough for the collar to seat and done.....

[Wombat North]

My post before maybe wasn't clear enough. The thread on the TurboXS probe is 10mm dia x 1.25pitch x 16mm long. It is a "straight" thread not tapered.

[DISCOPOPE]

also, just because i know 'someone' who did this.
mark the side of the manifold to drill with a marker or crayon before you take it off..

sucks to know you just spent 30 min tapping the wrong side....

[paperchasin]

Great writeup!!! I vote for FAQ!!!

[MattSTi]

"The base should fit tight and have at least 1/8" visible" vs. "Tap just enough for the collar to seat"

What's the reason for leaving some of the thread visible?


I definitely think this is FAQ material.

[Unabomber]

It's FAQ approved! However this should probably be moved to the Electrical & Lighting forum for the best viewing. Pirana, you should also submit this to www.scoobymods.com as well.

[Wombat North]

Seems you guys like pictures

Below is a TurboXS EGT probe that has the 10mm thread. Since everyone wants to use a 1/8"NPT tap to do it you will need/can do this.




By doing this you can go back to useing most EGT probes as they are usually 1/8"NPT or you can upgrade to the TurboXS probe without messing up the 1/8" NPT hole you had.

[Uncle Scotty]

Originally Posted by MattSTi

"The base should fit tight and have at least 1/8" visible" vs. "Tap just enough for the collar to seat"

What's the reason for leaving some of the thread visible?


I definitely think this is FAQ material.

Tapping the hole just deep enough so that the probe tip is in the middle of the manifold is the reason, here. Tap too deep and the probe tip gets too close...or even touches .... to the far side of the manifold........BAD JUJU

[WolfPlayer]

I just ordered the Manifold to Head gasket and the Crossover Pipe Gasket. Here are pics along with part numbers:

http://www.bescaredracing.com/sti/exhaust/soa/gaskets/

[Pirana]

My reason is if you go too far, it can stay loose since threads will be wider than the nipple and it cant go farther down. This is the way we have been doing them on our heavy duty equipment at work for ages.

[LuvJuggs]

I have a catted Helix Downpipe with an o2 bung (used by stock sensor) and a bung in the bellmouth. I have a egt probe i want to mount here anyone know what the thread size in this bung is?

Thanks

[Uncle Scotty]

Originally Posted by LuvJuggs

I have a catted Helix Downpipe with an o2 bung (used by stock sensor) and a bung in the bellmouth. I have a egt probe i want to mount here anyone know what the thread size in this bung is?

Thanks

waste of time

[WRXDriftR]

drill the manifold making sure you have a perfectly steady working surface. A drill press would be ideal, much better than an hand-held drill


Then use a tap with the handle to thread it.


During tapping, make sure you use cutting oil and reverse the tap direction a 1/2 turn every few revolutions to break up the ships that are stuck between the teeth.

and assemble



Its not hard if you know what to do.

CLEAN EVERYTHING OUT OF THE PIPE BEFORE INSTALLING!!!!!!!!!!!!!!!!


~Chris

[josh06wrx]

sweet, that pic says it all! thanks

[nhat]

perfect...i think i can handle this!

thanks for the info