flyrotary@lancaironline.net Mailing List Archive

If you already have an off center hole in the bolt, getting another hole on center will be almost impossible. The drill bit will always got to the point of least resistance, and the mechanical shock of the bit grabbing one side of the hole could break the bit. I know, did that years ago. I would have to agree with Mark, tearing it down might be prudent.

Bob Perkinson
RV-9 13B

From: Mark Steitle <msteitle@gmail.com>
To: Rotary motors in aircraft <flyrotary@lancaironline.net>
Sent: Tue, January 11, 2011 1:00:56 PM
Subject: [FlyRotary] Re: Broken Tension Bolt ... update

Jeff,

At this point I believe that I would bite the bullet and disassemble the engine. Those irons are too expensive to risk damaging.

Mark S.

On Tue, Jan 11, 2011 at 12:35 PM, Jeff Whaley <jwhaley@datacast.com> wrote:

Hey thanks Ernest, you shouldn’t have to do that, but I won’t stop you …

I’ve ordered two long bits, 5/32” and 3/16” for inside diameter … the outside diameter you could double-check with any housing, but 3/8” is a pretty close tolerance fit.

Jeff Whaley

100 Manion Rd,

RR#2 Carp, Ontario, Canada

K0A 1L0

From:

Ernest Christley <echristley@att.net>

Subject:

Re: [FlyRotary] Re: Broken Tension Bolt ... update

Date:

Tue, 11 Jan 2011 13:07:28 -0500

To:

Rotary motors in aircraft <flyrotary@lancaironline.net>

Ernest Christley wrote:

Jeff, send me a couple of measurements and I'll turn a collar that you can use as a guide to center the drill bit. The inside diameter would be the diameter of your bit. The outside would be the size of the hole.

From: Jeff Whaley
Sent: Tuesday, January 11, 2011 12:52 PM
To: 'Rotary motors in aircraft'
Subject: RE: Broken Tension Bolt ... update

So far no luck at getting the broken tension bolt threaded end out of the front casting. With help from Cary Beazley, we were able to back out the broken part a little bit with just pressure and mating the two surfaces together, until it jammed and would come no further. Not having (or knowing about) LH drill bits at the time, we decided to RH drill a pilot hole for an easy-out. Drilling the hole was no problem but getting it centered was, so it’s drilled off-center and the broken piece is now probably bottomed out in the casting. The easy-out is simply not latching onto the bolt. We’re going to borrow a bore scope to get a better look. After that I’ll have to make a long center-punch and try to make a new (centered) pilot hole with the long LH drill bits on-order (see link) … hopefully they’ll grab onto the part and extract it, otherwise it will be an engine tear-down, which I dread at any time but at -10C it’s no fun at all.

http://www.icscuttingtools.com/catalog/page_110.pdf

Jeff Whaley

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