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1G Prothane Poly Front Roll Stop Large Hole adaptor for using stock size smaller bolt

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Ok so I did a write up on how to easily remove your OEM rubber motor mounts and install Prothane Poly inserts. After I did my removal and install I noticed that on 1G's, the front roll stop insert has a much larger hole for the factory bolt to go through (2G's just use inserts that surround the factory rubber) that would create a lot of rattling because of how sloppy the bolt would be in that mount. I talked with others that did a "Big Bolt" swap but in my case I didn't have a lot of the engine roll stop bracket to work with since I had to cut some of it in order to clear my HX40 turbo drain and intercooler piping so I found a way to make an "adaptor sleeve" for that one mount so the factory bolt could be used without making a lot of rattling due to being so much smaller than the hole in the new mount. Here is a picture of the problem that maybe you are looking at too:

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So here is the "Fix" for that sloppy bolt hole.
You will need the following:

3/8" Drill Bit and Electric Drill
1/4" x 4" or 5" BRASS Pipe Nipple (You will only use 2" of it that is NOT threaded)
1/2" x 2" or longer COPPER tubing (I had to buy a foot for $2.99 and cut it to length)
WD-40 for cutting lube
Work gloves for handling hot metal tube
Round file OR Dremel tool with a small round stone for de-burring pipe and tubing
Hacksaw or Sawzall with a metal cutting blade
Tubing cutter or the saw above

Put the 1/4" BRASS pipe nipple in a vise and clamp it down, you are going to cut the threaded end off of one side with your saw because you don't want the threads, just the brass pipe. After you cut the threads off of one end, measure and mark 2" from the new bare end and cut the brass pipe to a 2" length of unthreaded pipe.
Next, put that 2" piece into the vise to hold it firm because you are going to "ream" the inside of the brass pipe.
Get your drill and 3/8" drill bit ready and lube up the bit and inside of the brass pipe with WD-40.
Start drilling through the inside of the brass pipe, lubing it up as necessary as you ream it out to 3/8". It is already close but not big enough inside for your factory bolt to go through, so you are now making it just large enough for your factory front roll stop mount bolt to go through. It will get VERY HOT so use your gloves so you don't burn the heck out of your fingers. Remove it from the vise and clean and cool it in water.
Now cut your 1/2" COPPER tubing to the same 2" length with a tubing cutter or your saw.
De-bur the BRASS pipe you cut and the COPPER tubing you cut with a round file or Dremel tool on the inside and outside so no bur's remain.

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Now you should be able to fit the BRASS pipe you reamed out into the COPPER tubing like this, making sure your factory roll stop bolt fits into the BRASS pipe as such:

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Now you are done, fit the 2 tube combination into the BIG hole in your new Poly Front Roll Stop like this:

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The fit should be darn near perfect like my picture above. Go wash your hands, grab a cold beverage and pat yourself on the back for a job well done (and use the cold beverage to cool your burnt fingers if you didn't use gloves and also as a sedative for the pain!)
I hope this helps everyone out that see's this as a problem on your 1G and of course if you need anymore explanation, just PM me if you don't understand something.
Good Luck and Happy DSM'ing!!! Marty
 
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