I am also afraid of dropping metal shavings down in it too

 

Personally I wouldn't do it with the head installed. I'd put it in a drill press. Metal shavings aside for a moment (which is a legit concern- your water pump won't like them, nor will your heater core), there isn't much room for error drilling in that spot. I've been working on motors for better than 35 years and I won't drill a head freehand. (so call me chicken, lol)

I'd do this instead:
http://hescosc.com/shop.asp?action=d...2#.Udo49_lwo_Y

Thermostat housing with two sensor ports. Move the existing sensor over and add the new one. Extend the connector from the firewall forward to the new sensor.
$32.95, 4 feet of wire, 4 crimp connectors and you're done.

 

Does this housing still use regular gasket as the OEM?

 

Yes. Same gasket as the OEM housing. The only difference is the second hole for the second temp sensor. It's a direct fit replacement for your current housing.

 

Sweet! Thanks. Now I just gotta wait till pays day to order my parts. I hate being broke

 

So I had planned to drill out a spot in thermostat housing to make it like the one shown in link but when I see the size of the sensor it looks like it may restrict water flow too much in that location to have both sensors hooked in. The copper tee thing is starting to look like like my best bet.

 

Id go with that housing posted above by the time you buy the other stuff and time involved it be cleaner looking and cheaper and a cleaner look.

 

Be very careful mounting the sending unit in that modified t-stat housing......the new sending unit and wire(s) location will be very close to the rad fan blades.



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Here's a pic of the home-made copper nipple/sending unit installed in 3/4" hose. Do it right and use split wire loom and the install will look neat and clean. Obviously this install is not on the XJ, but u get the picture I'm sure.



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Good point. Thanks guys

 

do u have more pictures and is it working