Ken,
Could you post some pictures? Please use a new Subject so we can find it
later.
Thanks
Rob Mueller
Sydney, Australia
75 - Avion
The Blue Streak
-----Original Message-----
From: Ken Henderson [mailto:ken0henderson]=20
Sent: Wednesday, 5 December 2007 2:33 PM
To: gmclist
Subject: RE: [gmclist] Edelbrock Olds Exhaust Crossover Plugs
Gordon,
A router coming apart at speed could certainly be hazardous!
I too have used wood routers on aluminum and fiberglass -- but never steel
or iron.

I think the machinist's tool speed recommendations are based
on speeds a fraction of a router's -- like 1/20th.
My 23' now has an electrical compartment door at the very rear, just above
the generator compartment. With the coach gutted, I noticed that there was
framework there resembling the doors I'd seen on 26' coaches. Sure enough,
when I measured, the dimensions were the same. So I bought a used door,
taped a plywood jig to the side of the coach, and routed out a section of
the aluminum for the door.
Fortunately, I set the bit depth barely more than the thickness of the skin
because when the plug fell out, there in the hole, already in place, was th=
e
foam rubber seal which would have been used to seal the door if GMC had
installed one! And the little 3/8"x1/4"x1/4" aluminum lock striker was
already welded in place on the lower stringer! I was truly astounded,
especially by the rubber.
I've never seen another 23' with that door; I've often wondered whether the=
y
all have the rubber and striker lurking back there.
Ken
> -----Original Message-----
> From: GRS [mailto:wizwing]=20
> Sent: Tuesday, December 04, 2007 10:02 PM
> To: gmclist
> Subject: Re: [gmclist] Edelbrock Olds Exhaust Crossover Plugs
>=20
> Ken;
> I have used the wood router to cut and shape all manner of=20
> things. I had one chatter on a fibreglas hull and the result=20
> was the commutator bars on the top end of the router came=20
> loose and the router exploded. At 20,000 rpm, stuff happens=20
> very quickly and violently. I had been using this Sears=20
> router on fibreglas many times without incident. I now use a=20
> air powered die grinder with carbide bits on these sort of=20
> jobs. If you spray the bits with a lubricant, metal doesn't=20
> stick and chatter is reduced.
> Gordon
> ----- Original Message -----
> From: "Ken Henderson"
> > Rob,
> >
> > I should have mentioned earlier a technique you're equipped to=20
> > implement and may like: I've been told that Alex & Jeff Sirum's=20
> > crossover plugging technique is to use a homemade plywood jig and a=20
> > wood router with carbide bit to machine recesses 1/8" or so deep in=20
> > the intake manifold. Fitted steel plugs are left just=20
> proud enough to=20
> > be clamped by the gaskets.
> >
> > I was skeptical of the machinery too until Alex confirmed it for me.
> >
> > Ken H.
>=20
>=20
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