Going to drill damper access holes for Tracksports, any specific type of bit to use? size?

Bahn S4 · 10-25-2005, 08:39 AM

***O.W. Kenobi*** · 10-25-2005, 08:42 AM

so that it doesn't walk all over the place.

Bahn S4 · 10-25-2005, 08:49 AM

ryans4 · 10-25-2005, 08:57 AM

...just drill a small pilot hole first, and lubricate the bit with WD40 or similar as it will heat up once you get through the aluminum and start working the two layers of steel.

Also, get some clear coat (or other color) protectant to spray the raw steel hole with to keep it from rusting.

Lastly, before you "call it a day", test out the hole, if you can't get it to work easy, then modify it before you put the car back together.

Watch out for the AC lines on the passenger side.

RKA · 10-25-2005, 09:22 AM

It eliminates the need for a pilot hole, and with several layers of metal to punch through, it makes the job a lot easier (I think). It also allows you to widen the hole progressively, until you've got it right where you want it. No swapping bits. I also found the unibit to be quite good at cutting through steel...better than some of the plain vanilla drill bits I have.

***O.W. Kenobi*** · 10-25-2005, 09:41 AM

It's hard to drill the hole perfectly straight.

Oo.et.oO · 10-25-2005, 09:51 AM

i wouldn't do that again and indeed only on one side.

i'd say it's not required. but if you can get the long one like steve says maybe that would speed the operation of shaving that metal out of there.

just use a punch to set the center of the hole and go to town with the proper angle using the string trick.

Oo.et.oO · 10-25-2005, 09:52 AM

will shavings go into the damper or just in the mount and wreak havoc?

RKA · 10-25-2005, 10:03 AM

I tried with some grinding bits. Eventually I found it easier to put a drill bit into it to widen it.

The metal shavings won't harm anything, but if you want to remove them (I would recommend it), get a small piece of metal wire, but a magnet on one end to magnetize it, and fish the other end in the hole to scoop up the shavings.

Captain Matt, I be · 10-25-2005, 10:06 AM

10-25-2005, 08:39 AM	#1
Bahn S4 Elder Member Account #: 53141 Join Date: Mar 2003 Posts: 14,626	Going to drill damper access holes for Tracksports, any specific type of bit to use? size? __________________ ------------------- Bahn S4's non-fried non-breaded wing recipe Diet and Exercise: Paleo + Crossfit

10-25-2005, 08:42 AM	#2
*O.W. Kenobi* R.I.P. Account #: 20137 Join Date: May 2001 Posts: 19,413	The instructions ought to tell you the size of the bit. Be sure to use a self-starting bit so that it doesn't walk all over the place. __________________ ======================================== My track videos * Brake FAQ * Kenobi lock pump * Kenobi hazard relay * Lidatek install * 43k oil analysis * 51k oil analysis * 60k oil analysis * 68k oil analysis * 76k oil analysis

10-25-2005, 08:49 AM	#3
Bahn S4 Elder Member Account #: 53141 Join Date: Mar 2003 Posts: 14,626	Yep, 9/16". Any specific bit material to look for? __________________ ------------------- Bahn S4's non-fried non-breaded wing recipe Diet and Exercise: Paleo + Crossfit

10-25-2005, 08:57 AM	#4
ryans4 Senior Member Account #: 4359 Join Date: Apr 2000 Posts: 7,314	Unibit's are nice and make the job easier, but a good 9/16" bit will do it... ...just drill a small pilot hole first, and lubricate the bit with WD40 or similar as it will heat up once you get through the aluminum and start working the two layers of steel. Also, get some clear coat (or other color) protectant to spray the raw steel hole with to keep it from rusting. Lastly, before you "call it a day", test out the hole, if you can't get it to work easy, then modify it before you put the car back together. Watch out for the AC lines on the passenger side. __________________

10-25-2005, 09:22 AM	#5
RKA Member Account #: 2062 Join Date: Mar 2000 Posts: 67,038	Another vote for the Unibit... It eliminates the need for a pilot hole, and with several layers of metal to punch through, it makes the job a lot easier (I think). It also allows you to widen the hole progressively, until you've got it right where you want it. No swapping bits. I also found the unibit to be quite good at cutting through steel...better than some of the plain vanilla drill bits I have. __________________ 2005.5 A4 Avant 2.0T Quattro 6MT APR 91/93/100 \| APR Exhaust \| 19" BBS RS-GT's \| Carbonio \| Hotchkis \| Partridge-in-a-pear-tree Others: 2006 TL on the block 2001 S4 sold 2000 A4 sold * September 11th, 2001 - Never Forget *

10-25-2005, 09:41 AM	#6
*O.W. Kenobi* R.I.P. Account #: 20137 Join Date: May 2001 Posts: 19,413	FWIW, I had to use a rasp on my holes to widen them a bit. It's hard to drill the hole perfectly straight. __________________ ======================================== My track videos * Brake FAQ * Kenobi lock pump * Kenobi hazard relay * Lidatek install * 43k oil analysis * 51k oil analysis * 60k oil analysis * 68k oil analysis * 76k oil analysis

10-25-2005, 09:51 AM	#7
Oo.et.oO Member Account #: 65580 Join Date: Nov 2003 Posts: 5,879	i used a FAT unibit before i knew there were others and blindly followed their instructions. i wouldn't do that again and indeed only on one side. i'd say it's not required. but if you can get the long one like steve says maybe that would speed the operation of shaving that metal out of there. just use a punch to set the center of the hole and go to town with the proper angle using the string trick. __________________ For Sale: B5 A4/S4 avant boot/trunk rubber mat Gone but not forgotten: 2001 Brilliant Black S4 Avant 6spd. c'mon AoA, where is the B8 3.0 TDi?

10-25-2005, 09:52 AM	#8
Oo.et.oO Member Account #: 65580 Join Date: Nov 2003 Posts: 5,879	sort of TJ: one of my holes is a bit off for the tool. bad to dremel it out now? shavings inside? will shavings go into the damper or just in the mount and wreak havoc? __________________ For Sale: B5 A4/S4 avant boot/trunk rubber mat Gone but not forgotten: 2001 Brilliant Black S4 Avant 6spd. c'mon AoA, where is the B8 3.0 TDi?

10-25-2005, 10:03 AM	#9
RKA Member Account #: 2062 Join Date: Mar 2000 Posts: 67,038	A dremel is a painful way to widen the holes... I tried with some grinding bits. Eventually I found it easier to put a drill bit into it to widen it. The metal shavings won't harm anything, but if you want to remove them (I would recommend it), get a small piece of metal wire, but a magnet on one end to magnetize it, and fish the other end in the hole to scoop up the shavings. __________________ 2005.5 A4 Avant 2.0T Quattro 6MT APR 91/93/100 \| APR Exhaust \| 19" BBS RS-GT's \| Carbonio \| Hotchkis \| Partridge-in-a-pear-tree Others: 2006 TL on the block 2001 S4 sold 2000 A4 sold * September 11th, 2001 - Never Forget *

10-25-2005, 10:06 AM	#10
Captain Matt, I be Elder Member Account #: 26545 Join Date: Oct 2001 Posts: 32,092	^^^always thinking. __________________ Support Innovation for the B5 Platform - www.autospeedperformance.com www.vastperformance.com B5 S4 Forum Cliff's Notes B5 S4 RNS-E Nav+ Installation

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