Go Back  HomemadeTurbo - DIY Turbo Forum > Homemadeturbo > Fabrication
homemade 5 bolt flange.. how should I cut the actual outlet hole? >

homemade 5 bolt flange.. how should I cut the actual outlet hole?

Fabrication Everything From JBwelded/Fluxcored downpipes to Equal length SS Manifolds.

homemade 5 bolt flange.. how should I cut the actual outlet hole?

Old 02-12-2009, 11:51 AM
  #1  
1.5 BAR
Thread Starter
 
Join Date: Dec 2006
Posts: 1,049
Default homemade 5 bolt flange.. how should I cut the actual outlet hole?

what's up noglets? I had planned on putting my hx35 on tomorrow, but I just realized the 5 bolt isn't the common ford 5 bolt pattern my downpipe is setup for. so, i'm going to pick up a miter saw and a steel cutting wheel for it, the only thing i'm not sure about is how to make the hole for the exhaust outlet..

any ideas? I could use a bigger drill bit and make a bunch of holes, and then cut the remaining bridges between the holes, but that seems like a waste of time. give me some advice please!


marcj is offline  
Old 02-12-2009, 11:55 AM
  #2  
3.0 BAR
 
Join Date: Sep 2004
Posts: 1,589
Default Re: homemade 5 bolt flange.. how should I cut the actual outlet hole?

Originally Posted by marcj
any ideas? I could use a bigger drill bit and make a bunch of holes, and then cut the remaining bridges between the holes,
I think I started to do that for mine, but instead borrowed an acetalyne (sp?) tourch and cut it out. Then cleaned it up with an angle grinder.

The next one for a wastegate I bought a hole saw and used a drill really slow with a ton of cutting oil. Granted the hole was much smaller you may burn up the hole saw before you make it through.

Weir sells the correct hx35 flange
stenseltizm is offline  
Old 02-12-2009, 11:56 AM
  #3  
1.0 BAR
 
Join Date: Dec 2005
Posts: 397
Default Re: homemade 5 bolt flange.. how should I cut the actual outlet hole?

a large hole saw and a drill press?


i would say just buy the flange but give it a shot.


turbob16hatch is offline  
Old 02-12-2009, 12:28 PM
  #4  
1.0 BAR
 
SiFlyBy's Avatar
 
Join Date: Dec 2005
Posts: 206
Default Re: homemade 5 bolt flange.. how should I cut the actual outlet hole?

I foolishly bought a piece of 3/8" steel scrap for $6 and spent 2-3 hours cutting, drilling, torching, cutting drilling, grinding, etc... I make over $20/hr, so what I ended up with is a warped as ---- piece of ---- that cost me over $60 to make...

Moral of the story: buy a ------- flange from wier.
SiFlyBy is offline  
Old 02-12-2009, 01:02 PM
  #5  
1.5 BAR
Thread Starter
 
Join Date: Dec 2006
Posts: 1,049
Default Re: homemade 5 bolt flange.. how should I cut the actual outlet hole?

lol.. i don't mind paying 10 bucks for one, but i was really hoping to get the turbo on tomorrow

i'll try the hole saw method... i'll go ahead and order a flange now incase it doesn't work out
marcj is offline  
Old 02-12-2009, 01:09 PM
  #6  
0.0 BAR
 
Join Date: Aug 2007
Location: Okotoks, AB
Posts: 0
Default Re: homemade 5 bolt flange.. how should I cut the actual outlet hole?

I have made a few flanges, the most recent was the hornet. It has to be really ghetto like the hornet, before I will bother making a flange. If you are dead set on it, a drill press is a must. Hole saw is the easiest for making a round hole, and don't be worried about following the contours of the turbo, as long as you have the space around it. the easiest way I have found for transferring the bolt holes is paint the turbo outlet (shove a rag against the turbine wheel, press against turbo well still wet, and there are all your holes, where you need them.

One last hint, test fit the flange before you put the turbo on the car, and clearly mark which way faces the down pipe, and which side faces the turbo. :1
HomeMadeTurboz is offline  
Old 02-12-2009, 01:12 PM
  #7  
1.5 BAR
Thread Starter
 
Join Date: Dec 2006
Posts: 1,049
Default Re: homemade 5 bolt flange.. how should I cut the actual outlet hole?

why is a drill press the only way? why not drill the bolt holes with a good bit, electric hand drill and some lube?? start small and step up

i do like the marking idea.
marcj is offline  
Old 02-12-2009, 01:21 PM
  #8  
0.0 BAR
 
Join Date: Aug 2007
Location: Okotoks, AB
Posts: 0
Default Re: homemade 5 bolt flange.. how should I cut the actual outlet hole?

The hole saw is a real BITCH with a hand drill. It typically stalls out with a 3/8"s drill and typically breaks wrists with a 1/2" one, but giver ----, and let us know how it turns out.
HomeMadeTurboz is offline  
Old 02-12-2009, 01:27 PM
  #9  
1.5 BAR
Thread Starter
 
Join Date: Dec 2006
Posts: 1,049
Default Re: homemade 5 bolt flange.. how should I cut the actual outlet hole?

true.. yeah I don't have a press, so i'll most likely just do what I can, and take it and the bit to someone with a press. thanks
marcj is offline  
Old 02-12-2009, 10:16 PM
  #10  
0.5 BAR
 
Join Date: Oct 2006
Posts: 79
Default Re: homemade 5 bolt flange.. how should I cut the actual outlet hole?

Just make sure you use a HSS hole saw. I kept making the mistake of using the high carbon saws until I realized steel absorbs carbon under high heat. Hense my long list of hole saw failures before I used hss <---me dumbass
chronic is offline  

Thread Tools
Search this Thread
Quick Reply: homemade 5 bolt flange.. how should I cut the actual outlet hole?


Contact Us - Sitemap - Advertising - Cookie Policy - Privacy Statement - Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.