jp4 in saxo vts inlet manifold drilling

1. craggy Newbie Joined: Mar 2005 Posts: 27

   #1 7th May 2013, 00:13

   Hi,
   
   The kids were in bed and the wife was doing the ironing tonight so I decided this was the time to drill, tap and fit my j4 inlet manifold to my jp4 head.
   
   everything went well to some extent, it fits like a glove, all 9 bolts have got a hold an its nipped up, however the front, top, left hole (as you look at it whilst drilling) I went to deep and hit a void. I thread locked the bolt and hovered out the swarf, but to save me a future job of finding out the hard way does this head need scrapping or is it ok?
   
   Im not really sure what chamber I have exposed with the drill?
   ta
2. blackie_2k5 Saxperience Hardcore! Joined: Oct 2008 Birtley Posts: 22253 VTR Turbo, 106 xsi track slag, Transit recovery, B

   #2 7th May 2013, 00:57

   Probably a water way/jacket or oil gallery.
   
   Get a pic if poss.. More then likely fucked.. But post a pic.. Stick something in the hole as far as it'll go, then measure how deep the hole is
3. monka Established Member Joined: Sep 2010 Posts: 1368

   #3 7th May 2013, 07:32

   I dont get why people drill and tap the head, when you really dont need to, cutting a a couple of penny shaped parts out of the standard gti/vts manifold is all you need to do
4. gazza808 Frequent Poster Joined: Jul 2007 Posts: 591

   #4 7th May 2013, 08:15

   How deep have you drilled it?
   Could you get a very short grub screw, smash some hydraulic hitemp thread sealant or or donkey tape on it and bottom it out in the bottom of the hole?
   Or is it a full through hole?
5. user_29491 Saxperience Forum Bum Joined: Dec 2008 Lancs Posts: 4124 JP4S'd R.

   #5 7th May 2013, 08:26

   Quote:

   Originally Posted by monka I dont get why people drill and tap the head, when you really dont need to, cutting a a couple of penny shaped parts out of the standard gti/vts manifold is all you need to do

   I don't even have any holes drilled in!
   
   Just some weird brackets to clamp the inlet on when the holes aren't lined up. Like they had on the actual C2 VTS
6. craigbarley Infrequent Poster Joined: Feb 2013 staffordshire Posts: 133 saxo vts (2000 single plug&mk2) and a civic type r

   #6 7th May 2013, 09:20

   Quote:

   Originally Posted by monka I dont get why people drill and tap the head, when you really dont need to, cutting a a couple of penny shaped parts out of the standard gti/vts manifold is all you need to do

   Monca that's cutting these penny shaped parts out do?
7. craggy Newbie Joined: Mar 2005 Posts: 27

   #7 7th May 2013, 10:24

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8. craggy Newbie Joined: Mar 2005 Posts: 27

   #8 7th May 2013, 10:30

   I ended up drilling and tapping because I had pdf'd two guides and both had it down as drilling. bloody annoying that the last one I did I went a bit far in (didn't read the guide properly!), oh well live and learn.
   
   I didn't realise you could do it any other way. I have basically covered that threaded bar that is in there in instant gasket and tightened it up as much as I could. will just have to try getting a nut on it now (its the top left hole which I think should normally be a bolt) if it don't work i'll have to throw it in the bin and start again with the notching method or learn to drill properly
9. monka Established Member Joined: Sep 2010 Posts: 1368

   #9 7th May 2013, 10:34

   Quote:

   Originally Posted by craigbarley Monca that's cutting these penny shaped parts out do?

   allows you to fit the standard gti/vts inlet manifold using that standard jp4 inlet bracketry, just cutting little bits out of the webbing on the actual manifold, not the head, so that you just use standard brackets and dont need to fuck about drilling holes and shit, and ending up doing as described in op
10. craggy Newbie Joined: Mar 2005 Posts: 27

    #10 7th May 2013, 11:50

    I still cant work out what the void is, im hoping its as per what blackie has suggested, I have gone right through by the way, cant really get a better pic unless I dismantle the lot. think I might have to just start the thing and see if it works, pain in the arse if it doesn't its a 30k 2007 jp4 lol a little hobby of mine gone wrong it seems
11. gazza808 Frequent Poster Joined: Jul 2007 Posts: 591

    #11 7th May 2013, 13:02

    Tbh if you stick a stud in it with some sealant etc on it chances are it'll be fine, just keep an eye on it.
12. user_9396 Established Member Joined: Apr 2006 torquay (England) Posts: 1993 supercharged vts. 1.1 saxo. accord type r

    #12 7th May 2013, 15:46

    just be carefull not to block or restrict the flow with the stud if it is a water or oil way that could cause you some issues..
13. ThrushMotorsport Established Member Joined: Jan 2011 Aberdeen Posts: 1092 Turbo Saxo vtr, 2010 Octavia VRS TSI, mk3 Ibiza cu

    #13 7th May 2013, 16:17

    You could have hit something, however, maby next time its practice to measure it, then wrap a bit of tape round the drill bit to tell you where to stop
14. user_39821 Saxperience Forum Bum Joined: Dec 2009 Uckfield, East Sussex Posts: 3362 Citroen saxo 1.4 furio

    #14 7th May 2013, 16:41

    I'd get a new head. Not very expensive and it sounds like a water jacket to me. you'd have to be pretty unlucky to hit an oil way. If not make sure to flush both systems through before assembly. The swarf will still be lurking in there.
15. axsaxoman Saxperience Forum Bum Joined: Jan 2003 Scotland Posts: 3380

    #15 8th May 2013, 09:35

    If stud is good fit --then with sealer --(thread lock ) it will be fine
    you only need to drill in approx 18mm as the studs do not have thread that long ,but you need a little extra depth for the tap
16. craggy Newbie Joined: Mar 2005 Posts: 27

    #16 8th May 2013, 15:18

    Quote:

    Originally Posted by axsaxoman If stud is good fit --then with sealer --(thread lock ) it will be fine you only need to drill in approx 18mm as the studs do not have thread that long ,but you need a little extra depth for the tap

    Thanks all, with this new found confidence that it should not have caused mayhem in my cylinder head I am going to take the manifold off, remove the stud and my makeshift thread locker, and invest in the best thread lock product I can find and get the thing bolted together properly, also perform a flush (however that is performed lol)
    
    I have a complete j4 engine that i have the possibility of taking the cams out of to put in this JP4 but as I know nothing about cam timing I was going to leave them out and be happy just to get the engine to "work" in a saxo. I wonder if doing this swap will give me a view of my hole and any swarf, might push me to do the swap which brings more risk I didnt want but hey ho.
    
    FYI, im no mechanic, just happen to have a saxo that I wanted to take apart and rejuvinate, as its been stood over a year.