I've seen a few listed as capable of doing both metal and wood, but not many. Obviously use carbide tips.

Like you said, next best way would be to draw out a 2.375" circle, jigsaw it out with a metal blade, then use bench grinder to rount it out.

 

Most hole saws (if they are good heavey duty ones) will work on aluminum. The aluminum that the TB is made of is not that hard. We use hole saws on the acft all the time. Just go slow and use some oil to keep your bit cool. Another thing you could try is a stepped reamer. The deeper you go, the bigger the hole is. They work great on aluminum too. Just dont try either on steel!!! And as far as making new butterflies....lay masking tape out on the metal. Draw them out with a pencil (it will be alot more accurate than trying to use a marker). Cut them out with snips, die grinder, shear, etc. Use a hand file to file all the way down to your line on the tape. I wouldnt shortcut it and use a hole saw to cut them out. The blade is at least 1/16in thick, and it will bend up your butterflies. Take your time and make them exact. You could also drill the holes out and bolt them together so both of them are exactly the same. Shouldnt take more that 20min to make them with snips and a hand file.

 

Im a nub here, so excuse me. But what does exactly does a TB aftermarket do permormance wise? Cause i want more power under my hood. ASAP

 

well from what i get it increases airflow which translates into more power....correct me if i'm wrong.

 

Look at your engine as one big air pump. Everywhere there is restriction, means you pump less air(less power). Now if you open up where the air comes in, you will see a lil gain. But when you get a bigger more efficient TB, modded kegger/replacement intake, headers, free flowing cat and upgraded exhaust you will see a huge difference. As far as the TB by its self....better throttle response, maybe just a lil mpg, and about 1hp. Everything compounds itself and the more you do the more power you will get out of each mod.

 

yeah that's what i meant. LOL!

 

ok so if i want to put more power into my truck. Where should i start. i have a super 40 muffler but it has a whole in it so that dont help. But anyways, Where should i start at? For an intake i want the 14x3 but i cant seem to freakin find one. But where should i start? Chip? Exaust? Where?

 

Man you are going to get alot of different opinions on that one. My questions are simple 1) how much HP are you wanting and 2) how much do you have to spend? I would start there first.

 

I was just going to use a die grinder on the TB, because the openings (and butterflies) have to be D shaped due to the divider.

I'm not greatly handy with snips- do you just cut a 2.25" hex/octagon and file/grind it down from there?

Like i sai, the butterflies have to be done first so i can test fit them the 100,0000000,00,0 times as i bore it out to make sure there's a good seal.

I suppose i could try to slip one of our files and the tin snips in my truck when i go home this weekend...we have a drawer of files and 2 pairs of snips so my dad shouldn't miss em...shop is a disaster anyways. That way i can make them here in the dorm.

 

Yep....you got the general idea. Cut the big stuff with the snips and then hand file it all the way down to the line to make them perfect. Another thing you could do....if you didnt feel comfortable replacing the butterflies is just widen the bores all the way up to the seal and still use the stock butterflies. Just an idea....