subarurx yo Posted April 27, 2012 Share Posted April 27, 2012 im swapping to ej and i was wondering what kind of cast it is since i will be welding the holes and redrilling since i only found one shop that would mill for $120 and thats too much and a place told me 50 bucks for a dremal bit. so i was thinking i could do it at school, there isnt a mill but we got mig tig and stick welders. any suggestions? Quote Link to comment Share on other sites More sharing options...
Prwa101 Posted April 28, 2012 Share Posted April 28, 2012 (edited) I woundnt weld the holes up! Welding them changed the molecules structure of the metal and makes it even harder to drill. I just redrilled my ea flywheel for my ej22, took me a while but did it really nice. You going to want to get the little ej (templet) peice that comes off when you take the ej clutch or tqv off. It's a spacer with all the holes your going to be drilling. I have one laying around I could sell you for a couple bucks if you can't find it. All re drilling is its offsetting the ea holes outward to fit the ej, the ej is a larger diameter. Look at sjrs pictures of his redrilled ones to see what I'm talking about. And google images would have this too. :update this is what your doping to be doing. -sjr's The holes don't need to be welded up. I uses a cone dremml bit in a drill press, worked great after I figured out the right method. The dremml it self was large and eat the entire hole for me. But depending on what kind of dremml you have. Hope this help! Sjr does it for 95$ i think? Not to bad. But not bad doing it your self either if you have the time. Hope this help! -Prwa Edited April 28, 2012 by Prwa101 Quote Link to comment Share on other sites More sharing options...
GeneralDisorder Posted April 28, 2012 Share Posted April 28, 2012 (edited) Don't weld - you will create hard spots in the metal from the electrical arc and there's no need for it. Get an end-mill (4 flute center-cut) of the right diameter and punch out the holes in a drill press or mill. GD Edited April 30, 2012 by GeneralDisorder Quote Link to comment Share on other sites More sharing options...
Crazyeights Posted April 28, 2012 Share Posted April 28, 2012 FWIW SJR did the XT6 flywheel I used in my EJ conversion and did a beautiful job! One local shop wouldn't even touch it. Quote Link to comment Share on other sites More sharing options...
subarurx yo Posted April 28, 2012 Author Share Posted April 28, 2012 where's the easiest place to get the endmill? As I will probably go that route Quote Link to comment Share on other sites More sharing options...
subarurx yo Posted April 29, 2012 Author Share Posted April 29, 2012 ive checked the prices on the endmills and theyre way out of my budget, so im unsure what to do Quote Link to comment Share on other sites More sharing options...
GeneralDisorder Posted April 29, 2012 Share Posted April 29, 2012 You want a 13/32" end mill. Try http://www.mcmaster.com GD Quote Link to comment Share on other sites More sharing options...
WoodsWagon Posted April 29, 2012 Share Posted April 29, 2012 The bolt holes don't have to be perfect, as the bolts don't transfer the power of the engine to the flywheel. They just clamp the flywheel to the end of the crank, and it's the friction between the surface of the crank and the surface of the flywheel that does the work. Quote Link to comment Share on other sites More sharing options...
Gloyale Posted April 30, 2012 Share Posted April 30, 2012 I've done them with a dremel and a $15 carbide bit. I personally find the smaller ones work better. Make steady passes removing just abit of material each time. If you get impatient and try to "dig in" too much it will just overheat the bit, and the dremel. If you go slow and steady, it takes about 2-3 hours to do all the holes. Quote Link to comment Share on other sites More sharing options...
GeneralDisorder Posted April 30, 2012 Share Posted April 30, 2012 McMaster has end mills for about $30: 3056A24 - $27.90 That's a four flute, center cutting, HSS endmill that will punch out the holes on a drill press in about 15 minutes. GD Quote Link to comment Share on other sites More sharing options...
subarurx yo Posted May 3, 2012 Author Share Posted May 3, 2012 i know that knowone recomended it but i welded the holes shut and drilled new ones i tack welded the template and drilled in between the welds and it turned out ok it did take a while due to dulling the bit 15 times but i wanted to see if it could be done Quote Link to comment Share on other sites More sharing options...
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