Date:         Sun, 1 May 2005 11:35:40 EDT
Reply-To:     THX0001@AOL.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         George Goff <THX0001@AOL.COM>
Subject:      Re: Exhaust port bolt size needed ? Try This FIRST
Comments: To: kd5ceu@YAHOO.COM
Content-Type: text/plain; charset="US-ASCII"

In a message dated 4/30/05 9:53:32 PM, kd5ceu@YAHOO.COM writes:

<< While drilling out one bolt, I broke a drill bit. Is there a type of drill
bit that will drill thru the broken bit? If not, what is the easiest way to
get it out? >>

There is no easy way to get it out unless someone has come up with a handheld
EDM (electrical discharge machining) unit about which I don't know.

Try this BEFORE you go animal on it.  Get a pair of miniature needle nose or
round nose pliers, the smaller the better.  If you do not have anything this
small, regrind the tip of a standard pair without ruining the temper.  Scratch
around the broken drill with a scribe to see it there are any loose fragments,
remove them with a magnet and blow out the hole with some air.  Soak the mess
with some penetrant then carefully insert the pliers into the flutes of the
drill remnant so that you grasp the web of the drill.  Now, WITH A DELICATE
TOUCH, try rotating the drill remnant VERY SLIGHTLY back and forth.  If you sense
any movement, wiggle a LITTLE more.  I'm telling you, this requires a
DELICATE touch, so don't go berserk on the thing!  Once there is some movement in the
drill remnant, you should be able to back it out.  Again, use a light hand,
stopping if you sense any undue resistance and returning to the back and forth
action.

If that fails, try disintegrating the remnant with whatever (scribes, awls,
small pin punches, etc.) can fit into the hole along side of the drill and
remove the pieces as you go along.  You will probably have to extend the effective
reach of your magnet by holding it to a small gage iron wire and inserting
that into the confines of the hole.

Using a die grinder in this situation has its own set of shortcomings as the
burr will tend to walk off the hardened steel of the drill remnant.

George