The Murphy Builders Site

Wayne,

I had a friend drill out the axle on his lathe, for the main gear, to install
a grease zerk and he broke off a #30 drill bit inside the axle.

Any suggestions on how to remove it. We thought of using a left hand drill,
thought being it might back it out.

Bruce




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Been there done that! (unfortunately). Drill a hole from the other size at
say 3/16 until you just touch the broken off bit. Then use a punch and knock
the broken bit out. Then use a piece of 3/16 alum rod to fill the hole you
didn't want. Epoxy chromate or proseal will hold it in place to permanently
plug the hole you don't want!

Wayne

----- Original Message -----
From: <Legeorgen@aol.com>
To: <rebel-builders@dcsol.com>
Sent: Wednesday, June 09, 2004 10:06 PM
Subject: Re:Greasing wheel barings 1800 amphibs

Wayne,

I had a friend drill out the axle on his lathe, for the main gear, to

install

a grease zerk and he broke off a #30 drill bit inside the axle.

Any suggestions on how to remove it. We thought of using a left hand

drill,

thought being it might back it out.

Bruce




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Thanks Wayne, I'll give it a try! I thought of drilling it out from the other
side and put the grease fitting on that side and plug the brake caliper end.
But I didn't think of the punch and plug.

That's much better and the grease won't blow out the cotter pin hole on the
axle nut side the way I was thinking of doing it.

Last night I thought of plugging the whole thing and putting the grease
fitting in the wheel its self to fill the space with grease. That sounded to simple
and I'm not at the hanger to see if there is a problem with doing that. Any
reason this wouldn't work?

Bruce

p.s. When I removed the wheels and turned them over, about a 1/2 cup of water
poured out!




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That's fine Wayne, I have two graduations Saturday and a reception to attend
for my Daughter on Sunday, sooo... guess I'm not working on the plane this
weekend anyway. Thanks for your assistance.

Bruce




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At 10:06 PM 6/9/2004 EDT, you wrote:

Wayne,

I had a friend drill out the axle on his lathe, for the main gear, to

install

a grease zerk and he broke off a #30 drill bit inside the axle.

Any suggestions on how to remove it. We thought of using a left hand drill,
thought being it might back it out.

Bruce

Hi Bruce
I have read that it's possible to dissolve a steel bit out of a block of
aluminum by soaking the part in a heated solution of alum. The recipe is
dissolve as much alum as possible in a pot of boiling water, reduce the
heat to just below the boiling point and add your part, wait patiently as
it takes a few hours to get results but you will be able to see the steel
bubbling and eventually the steel will be dissolved without affecting the
aluminum.
I haven't tried this so if you decide to have a go a little experimenting
with some scrap would be a good idea. If I was going to try it I think I'd
use my backyard BBQ for a heat source and a glasswear pot so the alum
doesn't attack the container. Let us know if you try it and if it works or
doesn't. I'm really curious to find out.
Drew





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Bruce, I'll have a look at the assembled unit in the morning to see if
tapping the wheel makes sense and is easily accessible for the gun.

Won't get back to you until late tomorrow night or possibly sometime on
Saturday, as I am heading east in the early morning and will either be back
just before dark or Saturday sometime if it's too late to head home by the
time I get things taken care of at my Mother's.

Wayne

----- Original Message -----
From: <Legeorgen@aol.com>
To: <rebel-builders@dcsol.com>
Sent: Thursday, June 10, 2004 9:50 AM
Subject: Re: Greasing wheel barings 1800 amphibs

Thanks Wayne, I'll give it a try! I thought of drilling it out from the

other

side and put the grease fitting on that side and plug the brake caliper

end.

But I didn't think of the punch and plug.

That's much better and the grease won't blow out the cotter pin hole on

the

axle nut side the way I was thinking of doing it.

Last night I thought of plugging the whole thing and putting the grease
fitting in the wheel its self to fill the space with grease. That sounded

to simple

and I'm not at the hanger to see if there is a problem with doing that.

Any

reason this wouldn't work?

Bruce

p.s. When I removed the wheels and turned them over, about a 1/2 cup of

water

poured out!




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Any chance you can spot weld a 1/8" welding rod to the bit?

If the break is near the surface, an even better technique is to place a
nut or piece of steel with about a 1/8" hole against the end of the axle
(or a countersunk hole) and weld that to the drill bit. That will also
work on broken threading taps but it may take a couple of attempts. In
any case, after welding I'd suggest soaking some aluminum cutting fluid
into the hole and then bringing the axle up to perhaps the temperature
of boiling water before trying to turn it out. You don't want to heat it
to the point that will take out the heat treating.

Cutting fluid is essential for deep drilling aluminum. I sometimes drill
a stepped hole that gets smaller diameter as it gets deeper for a deep
hole in an expensive part. That is slow due to many shallow cuts and
lots of drill bit changing, but it also gets more cutting fluid in
everytime you back off the bit.

Hope I'm not repeating stuff that has already been said as I've only
been back on the group since last night.

Ken

Drew Dalgleish wrote:

At 10:06 PM 6/9/2004 EDT, you wrote:

Wayne,

I had a friend drill out the axle on his lathe, for the main gear, to

install

a grease zerk and he broke off a #30 drill bit inside the axle.

Any suggestions on how to remove it. We thought of using a left hand drill,
thought being it might back it out.

Bruce

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I had something like this to deal with and the info I read about recommended
nitric acid. After looking at the issues around handling the acid I tried
harder on other ways & eventually got the screws out by drilling carefully &
backing out the remains.

Dave

Drew Dalgleish wrote:

At 10:06 PM 6/9/2004 EDT, you wrote:

Wayne,

I had a friend drill out the axle on his lathe, for the main gear, to

install

a grease zerk and he broke off a #30 drill bit inside the axle.

Any suggestions on how to remove it. We thought of using a left hand drill,
thought being it might back it out.

Bruce

Hi Bruce
I have read that it's possible to dissolve a steel bit out of a block of
aluminum by soaking the part in a heated solution of alum. The recipe is
dissolve as much alum as possible in a pot of boiling water, reduce the
heat to just below the boiling point and add your part, wait patiently as
it takes a few hours to get results but you will be able to see the steel
bubbling and eventually the steel will be dissolved without affecting the
aluminum.
I haven't tried this so if you decide to have a go a little experimenting
with some scrap would be a good idea. If I was going to try it I think I'd
use my backyard BBQ for a heat source and a glasswear pot so the alum
doesn't attack the container. Let us know if you try it and if it works or
doesn't. I'm really curious to find out.
Drew

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--
David A. Ricker
Fall River, Nova Scotia
Canada






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