GoodDayForADrive
10-19-2006, 11:26 PM
I seriously cannot even begin to describe how much trouble I'm in.
Scroll down to the short version if you're in a rush...
So first thing is first, I started installing my turbo on monday. The entirety of monday was spent getting my exhaust manifold and downpipe off, and involved me grinding one of the studs in the head down enough to get the manifold off, and then pulling that stud out of the head.
Tuesday was when I noticed that the turbo manifold I have would not allow the turbo to clear the firewall. I overnighted an ATP manifold brand new so my turbo would clear, meanwhile I did some other stuff like injectors, chip, oil pan, etc, while I waited for the manifold to come in.
Wednesday I get the manifold in, get everything bolted on finally by about 2:30 AM or so.
Start the car up, oil light comes on. Turn the car off. Check underneathe, big puddle of oil, so I check my fittings and realize I forgot to tighten up my oil drain line off the turbo. Tighten it up, restart the car. Won't idle. My friend notices fuel bubbling out of the intake manifold, so I take off the manifold to cehck for leaks. Nothing. Finally we realize I forgot to plug in the throttle body sensor, so we rebolt the manifold, plug that in, restart the car. Idles and runs fine (I'm assuming the engine flooded itself not knowing how much air was coming in.)
Drove the car around to test drive it, runs fine. Take it out on a main road, only to find out that I have no 4th or 5th gear. Wtf? Bring the car home, and notice that the downpipe is not allowing the linkage to clear it. Simple fix, I just need to swap the turbo manifold over. No Problem. Went to bed.
Thursday (Today) I wake up and start unbolting stuff to get to the manifold. Everything is going great, flip the manifold over, start bolting it back on, and then a stud breaks off of the head. Great. Only way I have to get this out is to drill it, and hammer a tap in there to get it out. So I do. Get it nice and snug, go to turn it, and the tap breaks inside the stud. At this point I'm really thinking I'm in a nightmare. After trying many other things that don't work, my dad suggests that I just drill it out bigger, and use my friend's threading set to rethread a larger hole. Ok, so I try that, but even my metal bits won't drill through the hardened steel of the tap that is jammed in there. So I get the brilliant idea to drill a smaller hole, and then I could just use washers to make sure it holds onto the manifold decently. I drill a small hole, and start threading it. I'm thinking I'm home free, finally figured this thing out, when the threading tap breaks inside the hole. I just about lost it at this point. Now, I have just enough room to drill one more small hole and thread this part, so I decide to do this, and this time make sure I have enough room to thread pretty deep in there. Problem is, I drill too far, and coolant starts spirting out of the head. I about cried.
So basically, I threw together some JB weld, and stuck it in the hole, hoping that at the very least, I can bolt the manifold back up with 7 bolts later. I'm really at a lost to describe the terrible luck I have had the past few days. I'm not really sure if this is a vent, or a request for help, but I needed to tell someone, and you guys are the ones.
Short Version:
I drilled a hole through my head in an attempt to tap out a new bolt for the exhaust manifold, and now coolant is leaking through this hole. I attempted to JB weld it tonight, and will take a look at it in the morning. Any ideas would be great.
Scroll down to the short version if you're in a rush...
So first thing is first, I started installing my turbo on monday. The entirety of monday was spent getting my exhaust manifold and downpipe off, and involved me grinding one of the studs in the head down enough to get the manifold off, and then pulling that stud out of the head.
Tuesday was when I noticed that the turbo manifold I have would not allow the turbo to clear the firewall. I overnighted an ATP manifold brand new so my turbo would clear, meanwhile I did some other stuff like injectors, chip, oil pan, etc, while I waited for the manifold to come in.
Wednesday I get the manifold in, get everything bolted on finally by about 2:30 AM or so.
Start the car up, oil light comes on. Turn the car off. Check underneathe, big puddle of oil, so I check my fittings and realize I forgot to tighten up my oil drain line off the turbo. Tighten it up, restart the car. Won't idle. My friend notices fuel bubbling out of the intake manifold, so I take off the manifold to cehck for leaks. Nothing. Finally we realize I forgot to plug in the throttle body sensor, so we rebolt the manifold, plug that in, restart the car. Idles and runs fine (I'm assuming the engine flooded itself not knowing how much air was coming in.)
Drove the car around to test drive it, runs fine. Take it out on a main road, only to find out that I have no 4th or 5th gear. Wtf? Bring the car home, and notice that the downpipe is not allowing the linkage to clear it. Simple fix, I just need to swap the turbo manifold over. No Problem. Went to bed.
Thursday (Today) I wake up and start unbolting stuff to get to the manifold. Everything is going great, flip the manifold over, start bolting it back on, and then a stud breaks off of the head. Great. Only way I have to get this out is to drill it, and hammer a tap in there to get it out. So I do. Get it nice and snug, go to turn it, and the tap breaks inside the stud. At this point I'm really thinking I'm in a nightmare. After trying many other things that don't work, my dad suggests that I just drill it out bigger, and use my friend's threading set to rethread a larger hole. Ok, so I try that, but even my metal bits won't drill through the hardened steel of the tap that is jammed in there. So I get the brilliant idea to drill a smaller hole, and then I could just use washers to make sure it holds onto the manifold decently. I drill a small hole, and start threading it. I'm thinking I'm home free, finally figured this thing out, when the threading tap breaks inside the hole. I just about lost it at this point. Now, I have just enough room to drill one more small hole and thread this part, so I decide to do this, and this time make sure I have enough room to thread pretty deep in there. Problem is, I drill too far, and coolant starts spirting out of the head. I about cried.
So basically, I threw together some JB weld, and stuck it in the hole, hoping that at the very least, I can bolt the manifold back up with 7 bolts later. I'm really at a lost to describe the terrible luck I have had the past few days. I'm not really sure if this is a vent, or a request for help, but I needed to tell someone, and you guys are the ones.
Short Version:
I drilled a hole through my head in an attempt to tap out a new bolt for the exhaust manifold, and now coolant is leaking through this hole. I attempted to JB weld it tonight, and will take a look at it in the morning. Any ideas would be great.