drilling and tapping face of 203 to accept round pattern 465/208 adapter

[twoslo4five0]

this afternoon I got my 465/208 adapter seperated from the 465. I have a 32 spline 203 range box sitting on the bench. I stuck the range box face up and set the adapter on it to mark where I would be drilling holes. At that point I noticed there was about a 1/8th to a 1/4 inch of gap before the adapter would sit flat on the 203 face. My thinking is to go inside of the 208 adapter and clean it up a bit with the grinder. Anyone else experianced this issue?

 

[Hogback Fabrication]

Grind the inside of the adapter housing and use 12 point bolts on the bearing retainer, you may need to grind down some of the webbing on the bearing retainer too.

 

[twoslo4five0]

that's what I was figureing, any idea where to sorce those bolts local, or just order from mcmastercarr.

 

[twoslo4five0]

Man that was easy. Like 1 beer easy. I put my grinder in a vise with a flap disc and lightly hit the OD of the bearing retainer checking to see if it fit in the adapter frequently. Literally took like 10 minutes. No grinding needed for the adapter, Just the bearing retainer. Looked in the doubler I bought and it already had 12 point bolts so I robbed them, prefect fit

now onto the drilling and tapping, looks like one of the lower bolts (not the bottom) on the round pattern I wont be able to tap as it will interfere with the lower gear. Im thinking this wont be a issue with enough RTV but inform me if it will be.

 

[sweetk30]

don't forget the refrence pics here http://coloradok5.com/forums/showthread.php?t=253000

worst case put a stud in there and make sure the back don't go in to the gear .

 

[twoslo4five0]

jeez man, hell of a write up. we dont do details like that around here lol.

 

[sweetk30]

I was board when I did that and quiet shop weekend so lots of un interrupted time for pics .

 

[twoslo4five0]

ours are like, that there round piece goes back up that hole that looks like an egg. Usual response is "oh ok that makes sense now"

 

[twoslo4five0]

Well I started drilling and tapping today. Not as easy as I had expected. My first 2 holes some how ended up a tiny bit off so I had to enlarge the holes to get the bolts in. Still plenty of meat on the adapter where the bolts go through. Luckily the first 2 were up on top. Hit the 3rd hole on the dime.

Now after looking I wont be able to run a bottom bolt becasue it will get into the gears. I could go with a blind hole not all the way through, but really dont know if that is nessary. Now that leaves me the 2 lower holes at say 4 and 7 o'clock. Any idea how to mark thouse holes to drill? mabye some paint in the hole?