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 step by step guide to drilling EGR into a JDM head 
more drilling and spraying with lubricant
more drilling and spraying with lubricant
Viewed: 73 times.

once the bit has gone as far as it can on the top hole move to the side hole and start drilling
once the bit has gone as far as it can on the top hole move to the side hole and start drilling
Viewed: 81 times.

drill in as far as the bit will go and keep spraying lube.  sometimes helps to have another person there spraying while you drill
drill in as far as the bit will go and keep spraying lube. sometimes helps to have another person there spraying while you drill
Viewed: 77 times.

here is the EGR hole which goes into exhaust runner #4 mostly finished.  once the drill bit can go no further remove the jig from the head and start at the top again and drill down to meet the other EGR hole going sideways.  be careful to not drill through that hole and outside the head!
here is the EGR hole which goes into exhaust runner #4 mostly finished. once the drill bit can go no further remove the jig from the head and start at the top again and drill down to meet the other EGR hole going sideways. be careful to not drill through that hole and outside the head!
Viewed: 83 times.

another shot of the jig removed and ready to start drilling some more... YAY!
another shot of the jig removed and ready to start drilling some more... YAY!
Viewed: 83 times.

here is a pic of the top hole with jig removed
here is a pic of the top hole with jig removed
Viewed: 86 times.

here we are finishing up on the top EGR hole
here we are finishing up on the top EGR hole
Viewed: 79 times.

pic of top hole with alot of aluminum shavings around
pic of top hole with alot of aluminum shavings around
Viewed: 80 times.

here is a pic of the drill bit meeting the ottom hole... DO NOT DRILL THROUGH THE BOTTOM HOLE!!!
here is a pic of the drill bit meeting the ottom hole... DO NOT DRILL THROUGH THE BOTTOM HOLE!!!
Viewed: 82 times.

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