Need the NPT 1/8 Fluid Level Check hole/plug machined first!

 So they're mailing me the plug

Here's a picture of a 1/8 NPT plug. The diameter is about 3/8" even
though the plug is called a 1/8 NPT.  The "1/8" has to do with the
thread specification not the size of the hole.

The allen wrench is a 3/16".
 And I got the adjustable tap wrench today. I bought a plug but it wasn't quite the same kind - it was a cap instead of a countersink plug. I bought 3 clamps - to hold the thing down - but what to clamp to? I don't have a work bench or anything.... I might just STAND on it?

So far I only found this as Brass - locally. No steel. And I was not sure if MIP is the same as MTP - but it is...

 1/8 inch NPT is the most common size in reverse-osmosis clean water systems.

  3/8 Inch diameter

• Thread Size:  1/8 Inch

So this appears to be the SAME part as it's the same color and sold in auto parts store. But it's not stocked and they had to make a "request" to order it! So they don't even know if they can buy it! The store will call me if they can order it. Meanwhile PML said they are mailing me out the part! thanks

Heat Resistance Hard anodized coated parts can withstand short exposures of temperatures up to 2000 degrees centigrade due to the inert nature of the coating. Thermal Properties Hard anodized coatings exhibit very low thermal conductivity and expansion but excellent thermal emissivity

Oops - their website is "misleading" https://yourcovers.com/diffcover_11035.php

drilled and tapped with a 1/8 NPT hole.

No - as was explained to me:

 The "1/8" has to do with the

thread specification not the size of the hole.

OK I ordered this drill kit! https://www.homedepot.com/p/Drill-America-1-8-in-Carbon-Steel-NPT-Pipe-Tap-and-R-High-Speed-Steel-Drill-Bit-Set-2-Piece-POU1-8NPTW-DRILL/304750418 I'm calling around and the local plumbing wholesaler says they don't do fabrication. The metal fabrication shop says they don't do drilling. The two local hardware stores - the first one claimed he would do a 1/4 inch NPT. When I said I would bring in the tools for a 1/8 inch NPT - he chickened out and said NO. The other store said they're guy who could do it is not there today and then they backed off also. haha.

 https://www.dieseltruckresource.com/forums/3rd-gen-high-performance-accessories-5-9l-only-107/what-drill-bit-size-r-169267/

R High Speed Steel Drill Bit has a diameter of

According to the packaging on the tap it says use with a 11/32 bit.

OK - that's about 3/8 inch diameter since 32/4 is 8 and 12/4=3.

Makes sense now!!

https://www.dieseltruckresource.com/forums/3rd-gen-high-performance-accessories-5-9l-only-107/what-drill-bit-size-r-169267/

 

a "R" .339" as your going to get without actually having to find and buy one. An 11/32" is .343" so it's a little bigger.

OK - I already ordered that 1/8 NPT tap drill kit with the R drill bit - this morning.

I read that the drill bit in the Drill America Kit itself is not very strong. So I'll try looking for a stronger R drill. (so far no R drill's are stocked locally).

 

I used a 21/64" bit. It's .328" so it's about as close to a "R" .339" as your going to get without actually having to find and buy one.

The machinist I talked to says he does not do drilling and the two local hardware stores declined also. haha. So I'll get a 21/64 strong drill bit tomorrow if I can't find an R drill bit that's better.

thanks again for your help,

drew

YourCoversPML

15 hours ago

@Voidisyinyang Voidisyinyang Fyi, on the 11035, the fill hole is at the top and is not a fluid level check. For the fluid level check, machine a 1/8 NPT hole on the front face. There's a location at about 4 o'clock. Let us know if you need more info or see the webpage: https://yourcovers.com/diffcover_11035.php

Voidisyinyang Voidisyinyang 13 hours ago

@YourCoversPML thanks - is it possible to make a dip stick - so you could measure when it hits bottom - mark that length. Then externally measure the length of parallel to the level check on carrier. Then mark that length on the dipstick (so you have the difference from the top hole to the carrier hole parallel on the pml cover). Then fill oil - stick in dip stick - and keep filling until the dipstick level is achieve (at the carrier level length measured from the parallel line on the PML cover). Does anyone do something like this? thanks

Voidisyinyang Voidisyinyang 12 hours ago

@YourCoversPML the dealer level for 8 inch diameter is 2 quarts. So another "extra deep" diff at 8 inch diameter says to add an extra .4 quart. So 2.4 quarts to fill it. Do you have a similar "extra depth" addition to the normal amount?

Voidisyinyang Voidisyinyang 12 hours ago (edited)

@YourCoversPML I don't want to mess up machining the 1/8 npt hole. I've never done anything like that. I'll call you tomorrow - if you send me out the machined cover - for the $45 extra - then I'll just return (UNOPENED) the cover you already sent (or however you want to do it). We can work this out. thanks. I can just reorder a new one and return unopened the one without the level check hole/plug. And once you get it returned - you can reverse the charge for the first order. We can discuss this. thanks

Voidisyinyang Voidisyinyang 3 hours ago

https://www.gmpartsdirect.com/oem-parts/gm-differential-cover-12479377 So I'm hoping my track bar is not bend back - it's at an angle. This fit is gonna be TIGHT! haha.

Voidisyinyang Voidisyinyang 1 second ago

@YourCoversPML OK I talked to the phone office lady - just when you all opened. I explained the situation - wanted the "check level" 1/8 NPT hole to be made and sent out. So I will return the first order - UNopened - and the $45 extra charge can be added to the pending sale. We'll figure out how you all want to do the charges - and she said she would call be back soon. thanks