How hard is this???can you do it with the radiator in the car??Can you drill it from the bottom up??I'm wondering cause im thinking about doing it soon for my turbo install.Thanks

I'd give yourself a full afternoon because you'll have to take off the lower oil pan. I don't think you have to take off the radiator but it would make it easier. Taking off the oil pan is a pain in da ass....

Khiem

If you have a 90 degree drill, you might be able to do it with a short drill bit and by removing the radiator and leaving the condenser in. Best to pull both upper and lower pan to ensure that any aluminum is cleaned out of the crankcase. Start with a small drill bit and work your way up. Make sure you keep the drill bit lubricated and keep pulling the drill bit out to pull the shavings out as you drill deeper and deeper.

also, use an air compressor (if available) to pressurize the crankcase with air (close all oil vetilation) to help keep as many savings out of there as possible (you wont be able to clean them all out, no matter how hard you try)

try not to use too much pressure though.

use stepped drill bit sizes to minimize effort, start with a really small bit for starters, and work your way up. dont drill all the way through the block until AFTER you have drilled the hole to its correct size. this will also help minimize the time you have to use the compressor and minimize risk of shavings getting in there.

when you are done you can take the oil pans off to make sure none got in (although many people, such as myself, just left them on there, your risk and your decision)

Could you drilll and tap the hole, then put a cap on it in order to install turbo lines later? Like if i wanted to upgrade the radiator, i could drill the block while its out. Just asking because like the faq says dont do too many things at once... so i figure do these at the same time since the raditor is already gonna be off.

Heres my bible for turbo kit installation...

http://www.brazosport.cc.tx.us/~lshadoff/turbo/

Take your time and do it right the first time. Drop both oil pans. Removing the radiator makes things 100X easier, since it is a nice, straight shot and it is easier to see what you are doing. If you can't handle draining the cooling system and properly refilling and bleeding it, you have no business turbocharging a car. With the other stuff off the engine anyways, its only another 5 minutes to pull the radiator.

IMHO
Andris

I realy don't understand how you can drill the block without pulling the pans off?! I remember when I did my first one.. There was a TON of shavings that fell through.. And it was a PITA doing it even with the radiator out...
Travis

I also forgot to mention... Just pull off the bumper cover and metal bumper, AC condenser. AC is for sissys anyways and its only about 10 mins to remove the bumper. Makes the process rediculously easy. :)

A photo amidst the 36-hour straight through turbo kit install/design/construction including drilling/tapping the block and clutch job: http://www.monkey-r.com/andris/pages/IMG_2847.htm

more photos of drill/tap there too: http://www.monkey-r.com/andris/

Good luck
Andris

That is one dirty ass motor :o

You can actually move the condensor down under the engine somewhat without disconnecting the freon lines. The aluminum lines will give enough to make this happen. No need to really remove the condensor. Just remove the lines from the little plastic clips that guide the lines from the firewall to the radiator support and the condensor will be able to move down and under the engine. Works well and clears up the space to get at the engine block straight up. No need for a 90 degree drill either at this point.

To answer the question about drilling and putting on the turbo later, yeah, no prob. Just find a plug of the correct size to screw into the hole. And use some kinda sealant (I used teflon paste) to seal it up. I ran around with the hole drilled and pluged for almost half a year before i got around to putting on the turbo.

Khiem

Originally posted by unlucky
I realy don't understand how you can drill the block without pulling the pans off?! I remember when I did my first one.. There was a TON of shavings that fell through.. And it was a PITA doing it even with the radiator out...
Travis

read my post about the compressor. the compressed air makes it so that when there is a hole formed, it pushes stuff out, from the compressed air. i havent had asingle problem with mine.

Originally posted by eric96ser
That is one dirty ass motor :o

Dirt roads :)

andris