Westach gauge installation help

[LPChristensen]

I ordered the Westach combination boost and egt gage from Geno's and the single pod A pillar mount. I have never drilled into a manifold before to mount the 1/8 thermo coupler when there was a turbo involved. Anybody care to share any secrets with me that will allow me some peace of mind. I have visions of a large (relatively speaking) piece of the cast iron drill residue getting into my turbo and the happy folks at the Dealer saying bye-bye to me and my warranty, which I would understand. I guess you could remove the manifold but that looks like a major production, several hours of work to drill a one minute hole. Any tips/solutions will be greatly appreciated, thanks in advance.

 

[Steve M]

I'm very unpopular here ya see... I installed mine post turbo as my truck will remain stock for warranty reasons. The elbow is a mild PITA to remove but I like it there. Pics in readers rigs to the left...

 

[rbattelle]

Like Steve, I am a full-fledged member of the "I have a post-turbo EGT" club. We are a card-carrying minority around here! Also like Steve, I removed my stock elbow, drilled it, and re-installed it. Unlike Steve, I purchased a spare stock elbow from a TDR member just in case I screwed it up.



If you want to drill in the manifold with it still in-place, it can certainly be done. I believe you will need a right-angle drill to do it most effectively. Someone who has done this successfully is TDR member JHardwick. He is also a machinst, so he knows how to drill holes in stuff.



As I understand it, you want to use plenty of grease or wax on the drill bit, and go slowly. When you get to where the bit is about to penetrate the manifold, start the engine and have a friend hold some rags over the tailpipe. This should slow or stop the turbo from spinning, and build up lots of back pressure in the exhaust stream. When you finally break through, the chips will come flying back out of the hole, right into your face and eyeballs if you're not wearing a face shield. If you wore eye protection, just shut the truck off and tap the hole (again, lots of grease or, even better, wax on the tap), install the thermocouple, and you're all set.



If you failed to wear eye protection, ask the assistant who was holding the rags over the tailpipe to drive you to the hospital to have the iron removed from your eyes. :-laf

 

[Prairie Dog]

Here's a slightly different method. Drill it with the eng idling and the exhaust blocked except for a 1/2 hole to breath through. I used duct tape. WEAR EYE PROTECTION. I dont like using grease to catch the filings because it sticks inside the manifold and later melts allowing stuff to go through the turbo, just my opinion . After drilling, tap threads w/ the eng off (very hard to tap while its shaking). Magnetize a small screw driver to place through the hole and collect all the filings. It take a few attempts but you'll get everything out this way.



Scotty

 

[DIESELMAN]

I'm pre AND post, for post, drill the elbow from the BOTTOM side, inside the elbow curve, regular drill, just lay on your back and use eye protection. This keeps the probe out of sight too.



As for the Pre, just make sure your drill has a small amount of grease on it, and spin no more than 150RPM. If your drill is sharp you will have only a few very large slivers and they won't, can't, fall into the hole.



Use some grease on the tap and don't sweat the chips that may fall in, they won't harm or jam the turbo. Period. They will blow out when the engine is started, the Turbo is a lot tougher than everyone seems to think.

 

[rbattelle]

Echo what dieselman said... except the part about drilling the elbow in-place.

 

[DIESELMAN]

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Drilled in place from underneath the truck, just watch your eyes!

 

[Bertram65]

Mine is post as well. I drilled in place with a air powered right angle drill, there are a couple of pictures in my reader rig. I had not thought to drill from below that looks pretty nice.

On a similar note, I had always read the post turbo pyros were slow to respond, mine does not seem to be this way at all, if I floor it at 50 MPH, boost goes right up to 23Lbs and pyro goes to 700 degrees within 3 seconds, it normally runs about 350 to 400. Once I let off the temp goes back down within 5 to 8 seconds.

 

[Slow Six]

I drilled mine pre turbo. I drilled straight down from the top or the manifold on the back section of the junction or Y. I placed a pair of strong magnets beside the drill bit and the cuttings stuck to the magnets. After the hole was drilled and tapped I probed the manifold with a small pencil type magnet to pick out any cuttings that may have fallen in. That was 45000 kms. ago and no problems. It seems a little unnerving but if you are careful it should go well.