daggerdoggie wrote:
By the way, I also drill all the bolt holes slightly larger as well, so you can align things better. I believe I used both 1/2" bit for the very front hole and 9/16" for the others. Check for the mm equivalent on the template, but they are slightly larger. Also, file any rough edges with a round file and use a good-quality, high-zinc primer on any bare metal before installation.
The trickiest part is the brace on the A pillar. Get some extra stainless steel screws the same size because the ones they provide tend to break. Check the measurements several times and drill carefully. The hole in the brace should go around the stock screw well centered and for some strange reason, you will need to drill that hole larger than you think.
When you go to put it on, leave all bolts loose until you can get it all to line up. Also, make sure you put the secondary tube on before you tighten the bolts down or you will have to loosen them again...I know this all too well.
If your truck is a 2002 or newer, there is an inner fender brace that you will have to cut out. This is a bitch to do, but you need to remove that to get the secondary tube to fit correctly into the intake. The bolt on the secondary tube lines up perfectly with a square hole on the inner fender...don't drill a new hole for that.
Ok thanks for all the info! I went to HD and got the hole saw it was expensive!!! So I came up with an alternate that I might give a try first. I bought a metal cutting bit for the dremel tool... It says it cuts stainless steel and hardened metal and is tungsten carbide. So it looks like if im careful I can make the circle with it. I might give that a try and if it just doesn?t work out ill use the hole saw.
Now I do have a 02 so with that inner piece I need to cut out how did you do it? can I use a hack saw or a cutting disk with the dremel?
Trust me im totally checking at least 10+ times before I drill the first hole! Haha Thanks again for all the info!