WELL GOT THE 'R' BIT 1/8 TAP :ro) COORS THANKS TO HOOT ON THE HORN SHE'S DONE :D

how scary was it?

I think I'm going to remove the manifold. I just don't have the faith in a drill bit or tap with my luck.

cmc

A little scary but printed out HOOT METHED real easy

No need to remove the manifold. Just leave it running, use successive bits, and WEAR eye protection.

motovet's got the answer. It's a little spooky if you've not done it before on a spendy truck, but it works well. Just a quick thought for you, center punch the manifold and start the hole before you start the engine. The engine wobbles a bit while idleing, and that will allow the bit to do it's thing without wandering around. Also, you might consider starting the tap without the engine running so you get it started straight. Or at least that's how I did it. Biggest hassle for me was removing the fender liner required me to remove the front of the running board attach piece. Couple of beers max job time...:cool:

I strongly recommend a new and correct size drill. Don't scrimp on drill quality.

The drill size recommended with the instructions from Edge was in error and no matter how much I tried the tap was not going in. Very frustrating with a running engine etc. I looked at "Hoots method", used a larger drill size (by fractions) from what Edge said which turned out to be the correct size and all went well. I think it was "R" size.