[TR] 1965 TR4A - Looking to drill out a stud hole in block. Need recommendations on a drill guide/jig.

[Jeff Scarbrough]

I've been thinking of a flat plate with a tube welded to it.  Tube has the
ID of the drill you intend to use.  Put holes in the plate such that it can
be bolted to the good holes in the block.  Length of tube determines depth
of hole.

Kind of expensive for a solution you only need once....

If you had some help, a couple of machinist squares could guide you, and
tape on the bit controls depth.  If you're slightly off, you put that stud
in after the head is on.

On Sat, Dec 11, 2021, 18:35 Guy Huggins <guy.huggins at icloud.com> wrote:

> Howdy All,
>
> As part the head gasket replacement project, I need to address a
> wallowed-out and stripped cylinder head stud hole in the block.
> (If you were standing on the manifold side of the engine, it would be the
> one furtherest to the front, on the manifold side.)
>
> A stud goes in straight up and down until the top of the threads are even
> with the block, but it wiggles like hell.
> As you tighten the stud down further, the wiggle starts to go away, but
> the whole thing starts to cant back toward the rear of the block.
> This make it impossible to slide the head down over the canted stud.
>
> To fix this I intend to install a coiled insert.  (drill just 1/32”
> oversized, tap, install insert).
> I am hoping that someone from the list knows of a drilling jig/guide for
> the drilling phase.
> I know better than to attempt drilling out cast iron without a steadying
> device of some sort.
>
> Any and all tips and advice are welcome.
>
> The hole is 1 5/16” deep, and the threads of the stud measure 3/4”.
> It is basically threaded top to bottom.
>
> Thanks in advance.
> I hate it when you have to fix the unknown thing to fix the known thing.
>
>
> Kind Regards,
>
> Guy D. Huggins
> guy.huggins at icloud.com
> 817.454.6415
>
>
>
>
>
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