Carpokes Porsche Forum

I had to remove the 944 headlight motor the other day, and one of the bolts pulled out all the aluminum threads with it. As is my way, I created this drill guide to drill out the hole for a helicoil insert. M6 Helicoils take a 1/4" drill bit, and this jig ensures the hole you drill will be centered and straight.

Nice one!

You should get some steel 1/4 ID tubing cut to size, harden it with a torch and some light oil, and press it in there, that would be really slick

icb wrote: Fri Jul 19, 2024 10:08 am You should get some steel 1/4 ID tubing cut to size, harden it with a torch and some light oil, and press it in there, that would be really slick

In that spirit, McMaster sells precision drill bushings, which I used in the water pump stud drill jig linked below, since the stakes are so high when drilling into the block, and since the bit seriously wants to jump off the broken steel bit and over to the block's soft aluminum.

viewtopic.php?p=5085

For the headlight motor, it didn't seem worth it, but maybe that's just because there was no broken bolt in mine.

Tom wrote: Thu Jul 18, 2024 10:23 am I had to remove the 944 headlight motor the other day, and one of the bolts pulled out all the aluminum threads with it. As is my way, I created this drill guide to drill out the hole for a helicoil insert. M6 Helicoils take a 1/4" drill bit, and this jig ensures the hole you drill will be centered and straight.

944 Headlight Washer Pump Drill Jig by Carpokes.stl

Hey Tom, looks like you have the incorrect STL posted for this thread?

928Kyle wrote: Mon Feb 02, 2026 8:23 am

Tom wrote: Thu Jul 18, 2024 10:23 am I had to remove the 944 headlight motor the other day, and one of the bolts pulled out all the aluminum threads with it. As is my way, I created this drill guide to drill out the hole for a helicoil insert. M6 Helicoils take a 1/4" drill bit, and this jig ensures the hole you drill will be centered and straight.

944 Headlight Washer Pump Drill Jig by Carpokes.stl

Hey Tom, looks like you have the incorrect STL posted for this thread?

Yikes, I wonder how long that's been there!! Thanks for the heads up. I'll find the right file and post asap. Are you looking to use it?

Updated the first post with the correct file. Thanks for the heads up!

No immediate need, just adding it to my Porsche tools arsenal. Thanks for updating the file!