I went to a mufler shop to have a 2nd o2 bung welded on so I can install my wb02. They cut out the hole then put in a regualr O2 sensor to see if it fits, then they welded the bung on. Upon installation of the WBo2 sensor at home, I discovered a big problem, the wbo2 sensor's head is much larger than that of a nbo2 sensor and it could not fit through the hole. I would take it back to the shop but my time is very limitted. So I'm looking for ideas to widen this hole without screwing up the threads on the bungs. Any ideas?

 

You want to make a threaded hole larger without messing up the threads? I think thats impossible.

 

^^^that's what I was thinking.
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the bung/threadhole is at the correct size, it's the hole they have cut out of the exhaust pipe that is too small.

 

use a drill to eat up the amount you need off.

 

use a dremel or a die grinder and hog the hole out a little it shouldnt be hard to do without ------- it up.
steve

 

Okay, the o2 sensor should be 18x1.5 (metric). You're saying that the bung is mounted up there but the hole still has some backing of metal behind it?

Can't you just take a punch and a hammer and just knock the pieces out of the way? I think throwing a dremel into it might be bad, you could ---- up the threads of the bung.

 

yes, that is correct
That's my worst fear.

 

use a drill of the right size and you should be fine.

 

Just dremel carefully...nothing to worry about.