Threaded Gallery Plugs
 

Im building a few 4.0 engines based on new 993 factory cases. As the customer wanted the cases fully deburred, I had to remove the factory gallery plugs for cleaning purpose, along with the piston squirters. Ive never been a big fan of pressed in galley plugs, So I went with something a bit more positive and threaded the case/spot faced for aluminum sealing washers. All threads are metric, M24,M22,M18, M14, aside from the small drillings, I went with 1/8NPT
Thought I'd share the way i approached this. Thanks
David Gouk
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Very nice....I like your thinking.

Looks really clean.

Do you have any pictures of your fixture? It looks really well made.

Very nice!

I've often thought about buying all of the tooling to use ORB plugs, but just never bothered to do it. I have the ones used to make fuel rails and such, but not the whole set.

One question: how have you determined the plug depth (spring preload) on the pressure relief valve?
The factory plug had a specific spring perch, your plug would need to match that depth. I guess a simple spacer would work given proper attention is applied.
I guess my question: why replace that plug?

Hi Henry, the only plugs that have been replaced are the pressed in aluminium galley plugs. I will be using the factory steel plugs on the relief valves to retain the correct spring tension.

I will take some pictures a little later and put them up. Thanks

You're right..... I misinterpreted the bottom plug.

In regards to the plug in the last picture. Is it going to interfere with the fan or are you planning on notching the fan housing?

Its close, but clears. I had the plugs made for me by speedflow is Australia. They have made a lot of oddball one off stuff for me for the Toyota engines that I do. The challenge is the intersecting oil feed to the Number 7 main, The plug slightly overlaps the hole, but a small radius of the drilling regains the lost area.

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wont the main galley plug on the top front of the case interfere with the fan housing?

Very nice work. Thanks for showing your fixture. Looks like it is precision ground on all sides.

Your machine looks like a very nice mill. Is it a cnc/manual version? I just outfitted my knee mill with a centroid control.

Good catch. Different case but same mounting fan parameters.



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