Probably will have to do a pilot hole with a smaller bit first to get the larger one to get a bite. It is somewhat of a challenge to get any bits started on the curved part. Smaller, very sharp bit will be much easier to get started. Or use a center punch and put a dimple in it if you have one.

Oh, and drilling multiple holes (starting at 1/2 inch and doing 1 inch then 1.5 inch) - be sure you have a plan to get them all started. I think it may be hard to get another one started if you have a hole already...

 

Anyone in the DC area that has done this? If so please PM me so I can get a listen to the end product.

 

This is not a bad idea, I may try this.

 

I had the same problem to start, if you are using the drill you need to use very high rpms with very light pressure and it will cut through in a couple of minutes.

 

I think that if you guys are looking for a truely unique and exotic sound the whistle tips are the only way to go.

[media]http://www.youtube.com/watch?v=ccgXjA2BLEY

 

That's a good way to ruin a bit. If you're only doing one muffler and trashing the bit, it's fine. High speed with light pressure and metal drilling generally doesn't do much for too life without lots and lots of cooling. A dimple or smaller bit for a pilot hole would be a better solution.

 

I would listen to Brad, this was my first time drilling metal with a battery powered drill, I tried with a setting too low and it just would not cut well

 

It's optional to listen to either one of us really. One just has to ask themselves if if they are going to use the bit once or try and use it for other projects. I've been guilty of "one use bits" myself. At least until I ruined a couple of expensive bits.

 

I'm pretty sure my shop teacher told us slow, heavy and wet was the way to cut/drill stainless. That was at least a hundred years ago but I'll bet nothing much has changed.

 

Slow, heavy and wet? You sure he wasn't talking about his wife

 

So there is no one in the DC area that has done this mod

 

I'm the latest to join the TJW Mod Club Had the day off today, so I decided to stop reading about it and just do it

Took off my tips so I didn't scratch them, and bored a hole right through the pipe! It takes a little effort to get the initial pilot hole through the steel (yeah, Porsche doesn't skimp on their materials), but once in it was easy to open it up. I stopped at about 1 1/8" for now...the sound is definitely noticeable in a good way A nice, louder and deeper growl than before. I haven't had much of a chance to drive yet, so I can't say anything toward power yet.... All-in-all, a cheap, easy and awesome mod

 

I started with 1/2" holes a few months ago and finally had them opened up to 2" yesterday. Made another huge improvement on sound and appears to spool faster. You can also test the turbos now!

This is the best DIY out there and such cheap entertainment. What a compliment for my EPL tune. Can't imagine what a realbe haust would be like.

 

Buy a hole saw 2" with the bit in the center or without FOR METAL, get a small extension on your drill, the 2" hole saw actually holds itself perfectly at the bend and does work! You will have 2 perfect sized holes when done.

Tips: Dont use cordless drill unless you have extra batteries laying around

 

You'd have to have a long pilot bit in the hole saw to get the pilot hole going in the bend, then the dangerous part would be once you got the hole saw going, the pilot bit would penetrate the back side of the exhaust. This is the reason I went with the unitbit and extension rod.