Thread: Daddy Drill Bits

since you have already drilled so far and you are using a hand drill, i would be inclined to take it into an Eng shop to get it removed. sorry may be cheaper in the long run.

if it was me i would be taking it to work any way

Is it possible to weld a nut onto it and then unscrew the nut???
Andrew

slug_burner, PM sent. Here are the photos. I have no idea how to post photos on a PM so here they are.

The tc burr in the upper left corner is end cutting cylindrical.

clean it well, stick it in the wifes oven on as high as it can go. (you want to hit about 400 degrees)

pull it out and sit it over a small gas burner, hit the stud with freeze'n'release (in a well ventilated area) then have a go at it with drill out stud extractor.

ok thanks for all the tips. I have finally sorted it. After drilling slowly with a cobalt I manged to penetrate the stud but after all remnants were removed the hole was seriously oversized even for helecoil.

I filled it with Devcon FasMetal and sanded it back then drill and tapped that.. very happy with the result. Just hope it lasts.

I should be able to post some photos of the damaged hole and fix when I get onto my other computer later this evening.

If from the start I had the best tools and methods for the job (well described in this thread) it could probably have been saved with less damage but I'm happy to have found devcon!

The oversized hole.. not good.


Some tape over area to mask off, hole cut out with stanley knife.


In with the devcon goop


Off with the mask


Sand flat


Target aquired by mounting pump, painting the inside of the hole and bit of measuring.


Drilled, tapped and helecoiled




I also managed to sort the stud I had stuck in the timing case.. the stud was a way into the hole and sheared at an angle so could not get a center punch on it. Being hevily corroded I managed to flatten it some with a masonary bit and then had enough depth to install my shallowest of helecoils. Becasue the hole is now shorter by about 1/4 the new fastner needs a bit of a trim or maybe just a thick spring and flat washer. Either way it should be good for the torque and stand up to more than a few pump changes.

Bar any more unpleasant suprises I should have her all back together with new coolant and on the run before the weekends done! Could be in for some happy days

Well Done Mate ...
Sometimes it can't get any worse and then you can just go for it.

probably better than new now anyway
Stevo

for future reference
When a steel bolt is sheared into an aluminium part

First step is the weld a nut to the bolt/stud trick
The heat from weld will release the bind
The nut gives something to turn
Weld wont fuse the aluminium

Steve