Well, long story short is i was drilling out the pin's that hold in the exhaust sleves in my s5 non-turbo housing's so i could put in the turbo ones i bought. In the process of drilling i enlarged the hole enought to make me worry.



Ive only come up with 2 idea's myself which are



1. replace the sleves and use shorter pin's, and a friend of mine who is a rather skilled metal worker said he could tig weld some filler into the hole. The only problem i was having with this is how could i be 100% certin that i would be able sand/grind whatever the filler so it is flat enough that i dont get coolent leaks



2. Second idea was to use whatever the material is used in blocking off coolent passeges when people pport engines, i would put a small amout of that again ontop of a shorter pin, and with that i would easly be able to run a puddy knife over making it level with the rest of that face. Do these materials expand at different rates enough that this would cause a problem? Im assuming no being that they use it in large quantities but i want to ask anyways



Has anyone else experienced the same problem? Did they even worry?



The untouched housing looks to have 3-4mm holes where as the ones i drilled are pushing 7mm. These #'s are not 100%, the only tool's i have atm is a plastic school ruler.



-Jacob

should just have you friend tig weld a ball of weld on the pin and pull them out....

weld the holes shut or smaller and redrill?

The hole is 5mm.



Can't you find a larger pin?



Or tap it and use a small setscrew?