I'm looking for some ideas to plug up the SAI holes in the heads.

I have the fittings in there, but then decided to pull the SAI out and not run with it. I'm way past the point of being able to weld the holes in the heads shut.

So, I'm going to pull the fittings out and now I need some ideas on what to do. Has anyone found a bolt size that'll plug up the holes? Just weld the ends of the SAI fittings shut?

Ideas?

 

Take the fittings to your nearest Fastenal or similar store and they can match the size, then just get whatever length you want.

 

That works
Or change threads and use a plumbing plug

 

Yes, take the fittings and have the opening welded up inside, unless you can find caps for the fittings like he said above. Caps for the tops of the fittings would probably be cheaper than having them welded. I think the tubes are stainless.

The end that goes into the block is an odd fine thread size but you may be able to find a cap for top of the fitting without too much trouble.

I thought the thread sizes were in the rave, but not sure if that's where I found it before?
and it's been awhile so not sure where to look.

Did you look through the rave for sizes?

 

Not finding anything in the RAVE.

 

I've been poking around trying to find the size. If I do I'll let you know right away.
Take one fitting out and carry it with you to find a cap to screw on where the union nut would go.
If you have a specialty place like Fastenal you would probably have better luck.

 

ok, I found here that the threads in the head are 5/8" unf 20tpi


and I found this (page 270, #3)

"Models with SAI: Using a 5/8 in x 20 TPI ( threads per inch) UNF tap having a class 2A
thread, remove deposits from secondary air
injection adapter tappings in cylinder head.
CAUTION: Ensure that tap used has 20 TPI "


and finally on page 173 in the rave workshop manual we have, #3 under head gasket/Refit... same as above.

So... I guess that's it for a plug size to go in the head but, probably won't find one just anywhere. I'm betting Fastenal can fix you up if you have one local..... or McMaster-Carr if not

If you can't find a plug or bolt in that size you can still go with trying to find a cap for the fitting/tube or weld the tube inside.

If you find a plug or bolt to fit, use blue loctite.... careful with the threads in the head when putting them in...the aluminum is soft. I got a set of heads once with buggered up threads there.... so just a heads up on that.

 

Its a M16x1.25

Now to find some for sale local.....

 

that is a fairly common port size.
you can readily find bushings to convert to 1/8"npt, so a plug should be easy enough

 

5/8" x 20 tpi = 15.875 x 1.27 = M16 x 1.25 ±