Template for side pipe outlet

[bogster]

Hi,

Does anyone have a template or advise on the size of hole to be cut for the 4 into 1 dax sidepipes that penetrate the body? I've got the headers but worried I'll cut the holes to big! An idea of where on the body the hole is and how big would be useful.

Thanks

[dave]

Hi Colin.
To be safe cut a small hole that will be central (ish) to your down pipes and then open this hole out to the right size by looking up through the hole and sighting the sides of the down pipes. I have a sort of pattern but still finish them off like this.
It might look really neat when you have finished if you mike the hole really tight around your pipes but your engine will rock and under load will easily lift by 1/2" or more.

[slogger]

Originally Posted by bogster

Hi,

Does anyone have a template or advise on the size of hole to be cut for the 4 into 1 dax sidepipes that penetrate the body? I've got the headers but worried I'll cut the holes to big! An idea of where on the body the hole is and how big would be useful.

Thanks

Well look at that! Just logged on to ask the same question. Want to cut the holes in the body before the lump goes in as it will be tight for space.

Dax mk4 body with Dax supplied headers and side pipes.

No templates then Dave?

[dave]

Hi Ian.
Cut the holes from the outside, its definately the easiest way, I can't imagine how they could be cut from the inside.
I'm sure I've seen a picture in the kit car press of Nigel (Details) Dean cutting his side pipe holes. (I think the current issue of Kit Car? (Where's Den when you need him?))
Follow his instruction, it's bob on.

[slogger]

Originally Posted by dave

Hi Ian.
Cut the holes from the outside, its definately the easiest way, I can't imagine how they could be cut from the inside.
I'm sure I've seen a picture in the kit car press of Nigel (Details) Dean cutting his side pipe holes. (I think the current issue of Kit Car? (Where's Den when you need him?))
Follow his instruction, it's bob on.

Thanks Dave.

I'll take a look. Sounds good.

Its not so much the cutting from the inside of the wing, its trying to line up the headers and projecting the cut line then marking with pilot holes. Not much room and as I said before, it would be nice to get the body cut and other jobs done before I finally get all of the Cob,s parts back home at my address.

Damn builders!! Why are they so slow!

[snake_bitten]

Get one of them short magnetic laser levels put it on your header down pipes and mark where the dot is (make sure the thing is in line with the pipe). Then drill small pilot holes 25mm inside the outline then cut the hole and open out to give best fit (as Dave says 1/2" all round)

[skorpion]

I used also a template and aligned the headers and sidepipe.
It fitted nicely after some hours of sanding/grinding...

But after some runs...the headers tends to hang due to the weight of the sidepipe and the sidepipe will rest (melting) on the lower edge of the opening.
So my advise is to make it not too big in the begining..after several runs...check how it goes and in which direction you need to adjust.
Regards,
Andy

[slogger]

Thanks John and Andy.

Looks like the lump will have to be in the hole after all.