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he has a 1" hole so, it too big for 1" tap, i dont have my tap drill chart in fron of me, so i dont know what size drill size it would be, but 1" wont work. i would make a sleave and weld it in, then tap it for a 3/4" hiem joint. thats my opinion.
From what I can tell; I should have a . 687 opening and tap 13/16.
I don't have the tubing yet...
Trying to decide if I should go with the DOM and order as needed to get the right size to tap or just get some solid steel 'rods'. The solid rods are not as strong as the DOM correct?
DOM is crazy $$$ around here and hard to get. But I only want to do this once!
If you are going to use your 2" O. D. X 1" I. D. tube, you can tap them for 1-1/8" X 7 NC without needing a tap drill (tap drill size is 63/64").
If you wish to use a fine series thread, then I would suggest using a 1-1/8" X 12 NF tap. Again, the tap drill size (1-3/64") is just over the 1" I. D. of your tube, and I would just tap the tube without tap drilling.
In either case use a good tapping fluid (such as rapid tap or joskitch) to produce the cleanest thread possible.
I am making a set also for my 98 and wondering what size heims to get. 3/4 or 7/8? I am getting the 2" DOM with 1/2: walls. How do you go about getting 3/4 or 7/8 threads in a 1" hole? Do I need to weld a big nut on the end or use the inserts like mentioned above?