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want to drill and tap boss on np205

An industry standard ( they are variables and exceptions ) is 1-1/2 thread depth engagement of the diameter of the retaining hardware ;but you are working with a limited amount of material until you possibly make it a through hole instead of a blind one ( blind hole is what you want but I think there is enough material there to keep ya safe ).
You can mark off the proper dimension on your drill bit with tape as a guide to keep you from drilling to deep.
Also keep in mind that the tap you have there is not a bottom/finishing tap and the very bottom of your engagement will not have proper threads - but if you have enough hole depth to drill a little deeper than what thread depth is needed all will be well.

Keep in mind that a machinist shop can do this for most likely less money than acquiring another drilled case plus freight charges ( you had mentioned this in one of these post lately ).

Also don’t let this give ya’ a headache - if you are not wheeling hard where sudden high traction and plenty of frame flex is the plan than this bar is not a 100% necessary.
That being said I am a fan of these bars in any 4WD but on the average user most cases it wouldn’t matter if they were there or not. I think they are good insurance and effective but don’t be afraid of light wheeling without one.
This is what I need? It says bottom finishing tap. This one is tapered and they have one that isn't


 
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The tapered tap is used to start and tap open(pass through holes) It is best to start and mostly finish a blind hole with a tapered tap. Then use the finish tap to cut all the way to the bottom. If the hole is deep enough that the bolt will not get to the bottom 3 or 4 threads you can skip the finish tap.

I have never started new threads with a finish tap, I think it would be very difficult to start them straight
 
So get both?, the bolt length is pretty short. I think the non tapered one would be ok. Like the one that comes with the drill bit

Ideally, someone with a 205 that has the holes could stick a toothpick in there or something and let me know how deep that holes goes. Then I would know exactly what length to drill into and the proper tap to be used.

If you use 1-1/4 corse thread bolt, possibly that hole is 1-1/2 deep type of thing.. so the tap above in the set would suffice
 
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Remember, that’s the bolt length not the hole depth. Part of the bolt length will be eaten up by the thickness of the bar and a lock washer.
 
Remember, that’s the bolt length not the hole depth. Part of the bolt length will be eaten up by the thickness of the bar and a lock washer.
Yes... I'm going to drill 3/4 which seems to deep, and see where I'm at. Maybe 1/2 inch but that doesn't seem deep enough.
I've looked all over online and can't find the actual depth of the hole on 205 for that bolt

744FE07C-C574-49CF-AE34-04D8C3DC39FE.jpeg

74247213-C314-45E7-82FD-F8236EC58866.jpeg
 
Yes... I'm going to drill 3/4 which seems to deep, and see where I'm at. Maybe 1/2 inch but that doesn't seem deep enough.
I've looked all over online and can't find the actual depth of the hole on 205 for that bolt

View attachment 431505

View attachment 431506
You are only looking at the external boss only - there is also an internal boss as well.

Also, just as Wes stated the bottom/finishing tap is for just what the name implies and the starting tap name is called that for a reason - use both at the appropriate times and all will be well.

468DFEDE-2CC3-4996-9BF3-A53AC8FC16A3.jpeg
 
Yes... I've seen one pic of the inside from the guy who just drilled all the way through the 205 to mount the strut rod.

Haha. Well, at least for whomever needs this info it will be in this thread, instead of all the place where I've had to look. Hahahaha

Ordered the drill bit and both taps...
 
Yes... I've seen one pic of the inside from the guy who just drilled all the way through the 205 to mount the strut rod.

Haha. Well, at least for whomever needs this info it will be in this thread, instead of all the place where I've had to look. Hahahaha

Ordered the drill bit and both taps...
Just for reference this case is a non drilled unit from my beloved old 77 K/10 that had a 465 in front of it - It had a build date of August and so did the truck; must have been cutting production delivery times real close.

58384F05-07D2-497C-A575-CE9B5FEA2E8D.jpeg
 
I will say this topic has taken me all over the net. Even to the way back ck5, it is interesting seeing familiar names and ones not known at all. When clicking on their profiles a lot of people are long gone and haven't posted in many years..

Here is one
 
Brother...!!!! Thanks a million. You may have shaved a few more pages off this thread with that info.
Hahaha, your welcome. I’ve been following along and meaning to get under there for ya.
 
I can’t get a perfect read with stuff in the way but by eyeball this is the hole spread I’m seeing.
DCAB269C-C8C0-4E6E-A969-B866E7C09F2D.jpeg
 
AFF94463-8B00-45AF-A128-5CA3CFC4B2E7.jpeg

1.5” bolt, hole is 1 1/8” deep,

image.jpg

With no support rod the bolt bottoms out with this much sticking out.
 

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