Original 6560 kit drill bit size and template

[BuddyS]

Hello all,
I’m looking for the actual drill bit size the was included with the original 6560 stealth trans upgrade kit. There was a drill bit included with the template(6590). I know what the close fit and loose fit clearances are for a 4-40 screw and drill bit sizes. But really want to know exactly what size was included in the kit.
If anyone has this info or could measure ones they actually still have please let me know.
Also, was there any instructions other than the stealth transmission pamphlet that explained how to do the modification to the “A”chassis. I know it’s no hard task at all I’m just curious if associated had any literature on it.
Thanks all!

[juicedcoupe]

I don't know what actually came with the kit, but a 1/8" fits the holes in an original chassis perfect.

[jcwrks]

It’s a 7/64 bit. 1/8 is too big.

[juicedcoupe]

It’s a 7/64 bit. 1/8 is too big.

A 7/64 would probably be good, especially after the countersink was used. But a 7/64 hole is just slightly too small as is.

I just finished doing a frogshot mod on a Blackfoot diff with 4-40 hardware. The 7/64 hole was slightly too small to pass the 4-40 screw through it. I settled on using a 3mm bit, which is slightly smaller than a 1/8.

[BuddyS]

All,
I agree with all the suggestions on drill size but what I’m really after is the “exact size” that was included in the kit. I sure there may be someone that has this kit and contents to confirm???.
Thanks

[bluewormx]

All,
I agree with all the suggestions on drill size but what I’m really after is the “exact size” that was included in the kit. I sure there may be someone that has this kit and contents to confirm???.
Thanks

The exact size is 7/64 (0.111" or 2.81mm) I just measured my original, but I'm pretty sure jcwrk beat me too it ;p

[BuddyS]

Thanks all,
Did AE include any literature on how to modify the chassis with the template? Other than the stealth pamphlet build instructions.
I’m after the history here and how it was done back in the day. I’m curious if they included any information on drilling and counter sinking the holes. I know it’s a very simple and straightforward process but really after the history any docs.
Thanks again

[jcwrks]

No, and the manual in the Stealth kit doesn't mention or show you how to use the drill template either. What even more odd is that the 6590 drill template only includes the drill bit in the 6560 box kit. The retail header card pack is the template only.