MWF FEED
15th October 2022, 07:30 PM
Went to rotate tyres, and couldn't undo one of the wheel bolts. Of course, it was the one with a security head:
IMG_3368.jpg (https://metalworkforums.com/attachment.php?attachmentid=400140&d=1665818859)
Tried a 300mm lever, wouldn't budge. Tried an impact gun, security socket just bounces off.
Tried a pipe on the 300mm lever, rock solid. Eventually, the slots on the bolt head become shrapnel.
So, try a cold chisel to knock the bolt head anti-clockwise. Half an hour later, the sacrificial top of the bolt breaks off. Didn't photograph it, was too busy swearing, but an un-mangled bolt looks like this:
Screen Shot 2022-10-15 at 6.59.15 pm.jpg (https://metalworkforums.com/attachment.php?attachmentid=400143&d=1665820868)
Another hour trying to chisel the rest of it around, including removing the other wheel bolts, bashing with weight off the tyre, et c., but no budge. Basically, the pocket in the wheel is too deep to allow a decent angle to turn the bolt head. So left it for a few days.
So, this arvo, spent an hour Dremeling a tiny indentation, then using a trashed 6mm ball nose Carbide in a cordless drill to enlarge it. Very slow going - this bolt is tough/hard steel.
Decided to take a risk. Grind indentation out to a taper with the Dremel, to make a safe pocket for this:
IMG_3366.jpg (https://metalworkforums.com/attachment.php?attachmentid=400141&d=1665820241)
A sharp 3/8" end mill in a cordless drill !!!
I carefully started, slow RPM, trying to be consistent with the pressure, and got a lovely pile of little needle sharp shavings. It went surprisingly well. This AEG brushless drill can do 2100RPM, so it went really well for the first 10mm. Shortly after that, the vibration started. I guess I lost one of the sharp corners.
So, tried a 9.5mm drill in there. Did nothing except polish the point on the drill. Back to the damaged Carbide cutter.
Vibration got progressively worse over the next 8mm, but made a deep enough hole to hammer an Ezy-Out™ into it, and wrench it out using the big tap wrench:
IMG_3367.jpg (https://metalworkforums.com/attachment.php?attachmentid=400142&d=1665820832)
In a perfect world, I would have had a carbide-tipped drill (maybe a sharpened masonry bit?),
but I was surprised how well a hand-held carbide mill cut!
Attached Images
https://metalworkforums.com/images/attach/jpg.gif IMG_3368.jpg (https://metalworkforums.com/attachment.php?attachmentid=400140&d=1665818859) (129.7 KB)
https://metalworkforums.com/images/attach/jpg.gif Screen Shot 2022-10-15 at 6.59.15 pm.jpg (https://metalworkforums.com/attachment.php?attachmentid=400143&d=1665820868) (43.6 KB)
https://metalworkforums.com/images/attach/jpg.gif IMG_3367.jpg (https://metalworkforums.com/attachment.php?attachmentid=400142&d=1665820832) (268.3 KB)
https://metalworkforums.com/images/attach/jpg.gif IMG_3366.jpg (https://metalworkforums.com/attachment.php?attachmentid=400141&d=1665820241) (148.2 KB)
Read the full thread at metalworkforums.com... (https://metalworkforums.com/showthread.php?t=208534&goto=newpost)
IMG_3368.jpg (https://metalworkforums.com/attachment.php?attachmentid=400140&d=1665818859)
Tried a 300mm lever, wouldn't budge. Tried an impact gun, security socket just bounces off.
Tried a pipe on the 300mm lever, rock solid. Eventually, the slots on the bolt head become shrapnel.
So, try a cold chisel to knock the bolt head anti-clockwise. Half an hour later, the sacrificial top of the bolt breaks off. Didn't photograph it, was too busy swearing, but an un-mangled bolt looks like this:
Screen Shot 2022-10-15 at 6.59.15 pm.jpg (https://metalworkforums.com/attachment.php?attachmentid=400143&d=1665820868)
Another hour trying to chisel the rest of it around, including removing the other wheel bolts, bashing with weight off the tyre, et c., but no budge. Basically, the pocket in the wheel is too deep to allow a decent angle to turn the bolt head. So left it for a few days.
So, this arvo, spent an hour Dremeling a tiny indentation, then using a trashed 6mm ball nose Carbide in a cordless drill to enlarge it. Very slow going - this bolt is tough/hard steel.
Decided to take a risk. Grind indentation out to a taper with the Dremel, to make a safe pocket for this:
IMG_3366.jpg (https://metalworkforums.com/attachment.php?attachmentid=400141&d=1665820241)
A sharp 3/8" end mill in a cordless drill !!!
I carefully started, slow RPM, trying to be consistent with the pressure, and got a lovely pile of little needle sharp shavings. It went surprisingly well. This AEG brushless drill can do 2100RPM, so it went really well for the first 10mm. Shortly after that, the vibration started. I guess I lost one of the sharp corners.
So, tried a 9.5mm drill in there. Did nothing except polish the point on the drill. Back to the damaged Carbide cutter.
Vibration got progressively worse over the next 8mm, but made a deep enough hole to hammer an Ezy-Out™ into it, and wrench it out using the big tap wrench:
IMG_3367.jpg (https://metalworkforums.com/attachment.php?attachmentid=400142&d=1665820832)
In a perfect world, I would have had a carbide-tipped drill (maybe a sharpened masonry bit?),
but I was surprised how well a hand-held carbide mill cut!
Attached Images
https://metalworkforums.com/images/attach/jpg.gif IMG_3368.jpg (https://metalworkforums.com/attachment.php?attachmentid=400140&d=1665818859) (129.7 KB)
https://metalworkforums.com/images/attach/jpg.gif Screen Shot 2022-10-15 at 6.59.15 pm.jpg (https://metalworkforums.com/attachment.php?attachmentid=400143&d=1665820868) (43.6 KB)
https://metalworkforums.com/images/attach/jpg.gif IMG_3367.jpg (https://metalworkforums.com/attachment.php?attachmentid=400142&d=1665820832) (268.3 KB)
https://metalworkforums.com/images/attach/jpg.gif IMG_3366.jpg (https://metalworkforums.com/attachment.php?attachmentid=400141&d=1665820241) (148.2 KB)
Read the full thread at metalworkforums.com... (https://metalworkforums.com/showthread.php?t=208534&goto=newpost)