This post covers the install of the front engine mount to the chassis.
Here is a video on the process…
First step was to make sure the rear engine mount bolts were tight and double checked that the front engine mount was square and in the correct position. Going to use 7/16” grade 8 bolts to attach the engine to the front engine mount and wanted to make sure the mount was aligned and those bolts just dropped right in to their holes.
Because the engine was moved back 1.5” there is only about 3” of space between the outside frame rail and the front engine mount. I was planning on using my Harbor Freight right angle drill attachment and simply drill out the frame rails with the engine mount in place, but there is just not enough room for a right angled drill head with a chuck…
So did a little searching and found the following combination of tools to do the job:
1)Dewalt MAXFIT Right Angle Magnetic Drill Attachment
2)Milescraft Metal Stubby Bit Set with 1/4 in. Hex Shaft (5-Piece)
3)Grand Rapids Industrial Products Titanium Coated Steel Step Drill Bit Set (3-Piece)
4)Removable drill bushing McmasterCarr part #8509A11
Pic of the Dewalt Right Angle attachment and drills below. Super compact and perfect for the job…
Because it is not possible to get a 3/8” drill into the rear outside holes decided to make a tool using a drill guide to make 1/8” pilot holes which would then be enlarged to 3/8” with a step drill…
Pressed the drill guide into a piece of 1/8” flat stock. Used a 3/8” piece of flat stock to hold the tool over the engine bracket so it lays flat against the frame…
The tool gets clamped on the frame and gets inserted into each hole on the engine mount. This assures that the drill guide is centered in the mount hole and is perpendicular to the frame rail. By doing it this way the pilot hole will be perfectly centered in each of the engine mount holes.
Pic of the drill and guide placed into one of the engine mount holes…
Well that was super easy and accurate. Pilot holes came out nice and centered…
After all the pilot holes were drilled I raised the engine and slid the engine mount out of the way. Then used a step drill to drill out the holes in the rails to 3/8”. I like the step drills since the holes are nice and round and do not walk.
Test fit the 3/8” bolts, they aligned well though the frame but were a little tight. To help the bolts slide through easier drilled out the holes with a regular 3/8” bit through the frame which helped aligned the holes…
Next step, getting the bolts through both the clamp and frame took a little persuasion. Ran a 3/8” drill through the clamp and frame on a couple of the holes that were not perfectly aligned. Pic of the bolts through the mount and frame. So far so good…
Installed the bottom C-brackets, they aligned perfectly without much fuss. Applied anti seize to the bolt shafts, washers and portions of the bracket that contact the aluminum frame. Secured the front engine mount with 3.5” long grade 8 3/8” bolts, washers, and lock nuts. All tightened up. Pic from the bottom…
Pic from the top…
All in all this process worked out well and am very happy it all lined up with zero play. In retrospect, it probably would have been easier to only do the pilot hole approach on the rear two outside holes. Then with the bottom c-brackets in place, just drill out the other holes with a right hand drill chuck and short 3/8” drill bit.
Checked this off my list and time to move on…