Vortec62
04-11-2006, 12:27 AM
I hate drilling holes in pieces of my truck so I came up with a little manifold that goes between the OEM pressure sensor and cast aluminum intake tube.
Materials:
3/8 x .035 aluminum tubing...about an inch
3/4 x 1 x 1.75 aluminum block.
3/8 x 1/16 o-ring
1 x 3/16 x 2 flat bar
M6 x 30mm capscrew
It's critical for the 3/4" space faces on the aluminum block to be flat & parallel. I sawed mine out of a 3/4" piece of aluminum flat bar.
what to do:
remove the pressure sensor and measure the location of the hole in the intake tube. drill a 3/8" hole through the aluminum block so that when it is set on the intake the hole lines up with the one in the intake. Counter bore the 3/8" hole with a 15/32 (not sure if this is right size...it should be same diameter as pressure sensor hole in intake tube). You'll need to go about 9/16" to 5/8" deep. Use a counter sink to put a nice chamfer on each end of the hole in the block. The pressure sensor should fit into the block just like it does on the intake tube at this point.
Flare one end of the 3/8" tube slightly and insert in the block so that it sticks out the bottom with the flared part resting against the bottom of the counter bore. This part took me some fiddling time...I used various punchs that had nice round tapers to "swage" the tube into the hole so that it is nice and snug. The initial flare is to ensure that the tube will not fall out of the block into the intake tube. Trim the tube so that it stick out about 1/4" from the block.
Drill a 5/16" blind hole into the side of the block. DO NOT break through into the hole already in the block. This hole will be for the 1/8" pipe fitting.
This next part is tricky...Drill 1/8" to 3/16" hole from the bottom of the 5/16 blind hole at an angle into the the other hole. You want to come out in the section where the 3/8" tube is. If you come out higher the seal on the pressure sensor will block the hole.
Tap the 5/16" hole with 1/8" npt.
The tube sticking out the bottom gives a place for the o-ring to be held. The chamfer in the bottom of the block and in the intake tube should seal nicely against the o-ring and prevent leaks.
I mounted it to the truck using a longer M6 bolt and a 3/4" spacer. The pressure sensor and OEM mount bracket where used. I also and a 3/16" piece of flat bar on top of the OEM bracket to apply more down ward force to compress the o-ring. See last picture. The spacer in the picture is a stack of washers with tape around them.
http://www.dieselplace.com/forum/garage_images/i8154.jpg
http://www.dieselplace.com/forum/garage_images/i8156.jpg[/URL]
http://www.dieselplace.com/forum/garage_images/i8157.jpg[URL="http://www.dieselplace.com/forum/garage_images/i8157.jpg"] (http://www.dieselplace.com/forum/garage_images/i8156.jpg)
Materials:
3/8 x .035 aluminum tubing...about an inch
3/4 x 1 x 1.75 aluminum block.
3/8 x 1/16 o-ring
1 x 3/16 x 2 flat bar
M6 x 30mm capscrew
It's critical for the 3/4" space faces on the aluminum block to be flat & parallel. I sawed mine out of a 3/4" piece of aluminum flat bar.
what to do:
remove the pressure sensor and measure the location of the hole in the intake tube. drill a 3/8" hole through the aluminum block so that when it is set on the intake the hole lines up with the one in the intake. Counter bore the 3/8" hole with a 15/32 (not sure if this is right size...it should be same diameter as pressure sensor hole in intake tube). You'll need to go about 9/16" to 5/8" deep. Use a counter sink to put a nice chamfer on each end of the hole in the block. The pressure sensor should fit into the block just like it does on the intake tube at this point.
Flare one end of the 3/8" tube slightly and insert in the block so that it sticks out the bottom with the flared part resting against the bottom of the counter bore. This part took me some fiddling time...I used various punchs that had nice round tapers to "swage" the tube into the hole so that it is nice and snug. The initial flare is to ensure that the tube will not fall out of the block into the intake tube. Trim the tube so that it stick out about 1/4" from the block.
Drill a 5/16" blind hole into the side of the block. DO NOT break through into the hole already in the block. This hole will be for the 1/8" pipe fitting.
This next part is tricky...Drill 1/8" to 3/16" hole from the bottom of the 5/16 blind hole at an angle into the the other hole. You want to come out in the section where the 3/8" tube is. If you come out higher the seal on the pressure sensor will block the hole.
Tap the 5/16" hole with 1/8" npt.
The tube sticking out the bottom gives a place for the o-ring to be held. The chamfer in the bottom of the block and in the intake tube should seal nicely against the o-ring and prevent leaks.
I mounted it to the truck using a longer M6 bolt and a 3/4" spacer. The pressure sensor and OEM mount bracket where used. I also and a 3/16" piece of flat bar on top of the OEM bracket to apply more down ward force to compress the o-ring. See last picture. The spacer in the picture is a stack of washers with tape around them.
http://www.dieselplace.com/forum/garage_images/i8154.jpg
http://www.dieselplace.com/forum/garage_images/i8156.jpg[/URL]
http://www.dieselplace.com/forum/garage_images/i8157.jpg[URL="http://www.dieselplace.com/forum/garage_images/i8157.jpg"] (http://www.dieselplace.com/forum/garage_images/i8156.jpg)