I wanna know how you broke *three*.
I mean - after you broke one... didn't a clue rake at least try to hit you
over the head about the rest of them?

-W



wrote in message
ups.com...
I over-torqued four bolts in the lower unit of an outboard, and the
heads of three bolts broke off. I managed to remove one of the broken
bolt using a Dremel tool and a diamond grind bit. But I cannot remove
the other two broken bolts using the Dremel tool. Based on the past
posts in this newsgroup, I learn that the best option in this situation
is to drill out the broken bolts. I would like to learn the details of
the way to drill out the broken bolts. My question is:

Which size of drill bit do I need? Should it be as large as the hole
where the broken bolt is?

Related questions:

The bolts are for securing the water pump housing for the
impeller. The hole for the bolt is at the edge of the water pump base
-- meaning that one side of the hole is kind of thin -- something like
3/32" thick. The bolt itself is like 1/4" or slightly larger. Because
I have over-torqued the bolts, I found that the holes pretty much losed
most of the thread. If I drill out the bolts, I probably will find
that the holes will become even larger. If I re-thread the hole after
drilling out the bolts, I am afraid that the holes will be even larger.
I am afraid that there will not be enough metal left. Is my
estimation correct? I am wondering whether I may be better off somehow
pouring in new metal into the holes and drill new holes instead of
rethreading/enlarging the existing holes?

The other thing is that there is supposed to have a gasket on top
of the surface. I am wondering if I rethread and enlarge the holes,
there may not be enough metal at the edge of the water pump base to
bite into the gasket and prevent water from getting into the bolt. Is
this something that I need to worry about?

Thanks in advance for any info.

Jay Chan

"Clams Canino" wrote in message
news

I wanna know how you broke *three*.
I mean - after you broke one... didn't a clue rake at least try to hit you
over the head about the rest of them?

-W


He broke the first two ... first.

Eisboch

"Eisboch" wrote in message
...

"Clams Canino" wrote in message
news

I wanna know how you broke *three*.
I mean - after you broke one... didn't a clue rake at least try to hit
you
over the head about the rest of them?

-W


He broke the first two ... first.

Eisboch


I know this because it's something I would do .

Kibosh

"Clams Canino" wrote in message
news

I wanna know how you broke *three*.
I mean - after you broke one... didn't a clue rake at least try to hit you
over the head about the rest of them?

-W


I was wondering the same thing. ;-)

"Clams Canino" wrote
I wanna know how you broke *three*.
I mean - after you broke one... didn't a clue rake at least try to hit you
over the head about the rest of them?

Not to jump on the jump-on-Jay bandwagon (he's got enough trouble with his
broken bolts already), but wasn't he the guy who asked what the difference
is between foot pounds and inch pounds a while back?

Ernest Scribbler wrote:
"Clams Canino" wrote
I wanna know how you broke *three*.
I mean - after you broke one... didn't a clue rake at least try to hit you
over the head about the rest of them?

Not to jump on the jump-on-Jay bandwagon (he's got enough trouble with his
broken bolts already), but wasn't he the guy who asked what the difference
is between foot pounds and inch pounds a while back?

Good Lord, give him credit for trying to do his own work. So he makes
expensive mistakes, I bet he learns from them. I have managed to break
5 drill bits in rapid succession.
Now, If I remember, there are special tools for removing broken bits or
taps. I suggest he look into a tool catalogue such as McMaster-Carr or
MSC.

Frogwatch wrote:
Ernest Scribbler wrote:
"Clams Canino" wrote
I wanna know how you broke *three*.
I mean - after you broke one... didn't a clue rake at least try to hit you
over the head about the rest of them?

Not to jump on the jump-on-Jay bandwagon (he's got enough trouble with his
broken bolts already), but wasn't he the guy who asked what the difference
is between foot pounds and inch pounds a while back?

Good Lord, give him credit for trying to do his own work. So he makes
expensive mistakes, I bet he learns from them. I have managed to break
5 drill bits in rapid succession.
Now, If I remember, there are special tools for removing broken bits or
taps. I suggest he look into a tool catalogue such as McMaster-Carr or
MSC.

I have several tiny hardened end mills from MSC. They are no wider
than a screwdriver blade and cost about $20 each and I have used them
for such tasks to get down into a bolt hole (using the dremel tool) to
make a screwdriver slot. You can also use the tiny diamond burr with
th dremel to make a "dent" atop the broken bolt for the drill bit to
start on when you drill it out.

Frogwatch wrote:
Frogwatch wrote:
Ernest Scribbler wrote:
"Clams Canino" wrote
I wanna know how you broke *three*.
I mean - after you broke one... didn't a clue rake at least try to hit you
over the head about the rest of them?

Not to jump on the jump-on-Jay bandwagon (he's got enough trouble with his
broken bolts already), but wasn't he the guy who asked what the difference
is between foot pounds and inch pounds a while back?

Good Lord, give him credit for trying to do his own work. So he makes
expensive mistakes, I bet he learns from them. I have managed to break
5 drill bits in rapid succession.
Now, If I remember, there are special tools for removing broken bits or
taps. I suggest he look into a tool catalogue such as McMaster-Carr or
MSC.

I have several tiny hardened end mills from MSC. They are no wider
than a screwdriver blade and cost about $20 each and I have used them
for such tasks to get down into a bolt hole (using the dremel tool) to
make a screwdriver slot. You can also use the tiny diamond burr with
th dremel to make a "dent" atop the broken bolt for the drill bit to
start on when you drill it out.

Yes, I used the Dremel tool with a diamond grind bit to form a slot on
top of one of the broken bolt, and I used a screw driver to remove that
bolt -- successfully.

But this didn't work for another two bolts that were sunk inside the
holes. The pointy grinding bit simply could not have a good angle of
attack on the bolt surface. What ended up happening was that the two
ends of the slot were slightly lower than the center of the slot and
this weakened the slot. When I used the screw driver to turn the bolt,
I ended up stripping the slot.

But this is kind of behind me now. As mentioned in my another reply, I
found an easy way to remove the broken bolts by simply removing the
water pump base, and this allowed the broken bolts to show up in the
open, and I used a channellock piler to remove the broken bolts.

Nice to talk with you.

Jay Chan

wrote:
Frogwatch wrote:
Frogwatch wrote:
Ernest Scribbler wrote:
"Clams Canino" wrote
I wanna know how you broke *three*.
I mean - after you broke one... didn't a clue rake at least try to hit you
over the head about the rest of them?

Not to jump on the jump-on-Jay bandwagon (he's got enough trouble with his
broken bolts already), but wasn't he the guy who asked what the difference
is between foot pounds and inch pounds a while back?

Good Lord, give him credit for trying to do his own work. So he makes
expensive mistakes, I bet he learns from them. I have managed to break
5 drill bits in rapid succession.
Now, If I remember, there are special tools for removing broken bits or
taps. I suggest he look into a tool catalogue such as McMaster-Carr or
MSC.

I have several tiny hardened end mills from MSC. They are no wider
than a screwdriver blade and cost about $20 each and I have used them
for such tasks to get down into a bolt hole (using the dremel tool) to
make a screwdriver slot. You can also use the tiny diamond burr with
th dremel to make a "dent" atop the broken bolt for the drill bit to
start on when you drill it out.

Yes, I used the Dremel tool with a diamond grind bit to form a slot on
top of one of the broken bolt, and I used a screw driver to remove that
bolt -- successfully.

But this didn't work for another two bolts that were sunk inside the
holes. The pointy grinding bit simply could not have a good angle of
attack on the bolt surface. What ended up happening was that the two
ends of the slot were slightly lower than the center of the slot and
this weakened the slot. When I used the screw driver to turn the bolt,
I ended up stripping the slot.

But this is kind of behind me now. As mentioned in my another reply, I
found an easy way to remove the broken bolts by simply removing the
water pump base, and this allowed the broken bolts to show up in the
open, and I used a channellock piler to remove the broken bolts.

Nice to talk with you.

Jay Chan

Glad to hear you worked it out Jay.

Sorry a non boat owner member here decided to flame you. But that is
his only reason he posts here. I would suggest you ignore him and any
*advice* he offers.. ;-)

"JimH" wrote in message
oups.com...

wrote:
Frogwatch wrote:
Frogwatch wrote:
Ernest Scribbler wrote:
"Clams Canino" wrote
I wanna know how you broke *three*.
I mean - after you broke one... didn't a clue rake at least try
to hit you
over the head about the rest of them?

Not to jump on the jump-on-Jay bandwagon (he's got enough trouble
with his
broken bolts already), but wasn't he the guy who asked what the
difference
is between foot pounds and inch pounds a while back?

Good Lord, give him credit for trying to do his own work. So he
makes
expensive mistakes, I bet he learns from them. I have managed to
break
5 drill bits in rapid succession.
Now, If I remember, there are special tools for removing broken bits
or
taps. I suggest he look into a tool catalogue such as McMaster-Carr
or
MSC.

I have several tiny hardened end mills from MSC. They are no wider
than a screwdriver blade and cost about $20 each and I have used them
for such tasks to get down into a bolt hole (using the dremel tool) to
make a screwdriver slot. You can also use the tiny diamond burr with
th dremel to make a "dent" atop the broken bolt for the drill bit to
start on when you drill it out.

Yes, I used the Dremel tool with a diamond grind bit to form a slot on
top of one of the broken bolt, and I used a screw driver to remove that
bolt -- successfully.

But this didn't work for another two bolts that were sunk inside the
holes. The pointy grinding bit simply could not have a good angle of
attack on the bolt surface. What ended up happening was that the two
ends of the slot were slightly lower than the center of the slot and
this weakened the slot. When I used the screw driver to turn the bolt,
I ended up stripping the slot.

But this is kind of behind me now. As mentioned in my another reply, I
found an easy way to remove the broken bolts by simply removing the
water pump base, and this allowed the broken bolts to show up in the
open, and I used a channellock piler to remove the broken bolts.

Nice to talk with you.

Jay Chan

Glad to hear you worked it out Jay.

Sorry a non boat owner member here decided to flame you. But that is
his only reason he posts here. I would suggest you ignore him and any
*advice* he offers.. ;-)


LOL. Let me rephrase that:

......But this is his the only reason he posts here...................