Topic: screwed up but good....

[HS]

So I tackle the folks today.  Things were going well.  Got the seal out and look at the fork...pretty grubby looking so I decide to learn how to polish aluminum....check.  Took forever but OK.  So I put the drain plug to the fork that goes in the side, to clear coat the fork after wet sanding and polishing, and without much pressure the damn thing snaps.  I noticed it was tough coming out all the way through it's thread, but the bolt looked find.

Try to tap it and that's when things went to #$%*....



Not my finest day.  I obviously wasn't centered and I went into the threads of the fork.  I drilled through eventually and tried to use an extractor and even that gave in there....tough to drill through.

Thoughts or straight to machine shop?

Sam

[boatsdickson]

Hope yur "folks" didnt mind being tackled as yu stated.  At my confidence and ability I think I would ask the machine shop how they would fix it and then do it myself. Yu have just created a learning experience....no biggie. Sorry not the best answer for ya but on this forum there are far wiser than me and better solutions will be along shortly.

[krusty]

It can be saved but you will most likely need to go up a bolt size. Where the ally has been drilled, is there any of the bolt thread left?
What I would do here (and have done in the past) is carefully file down what is left of the bolt (at about 1 o'clock in the pic) until just before the thread is reached. You can then, using a strong pick of some sort, pull/pry the remains of the bolt thread away from the ally thread. Depending on how deep you went into the ally thread you may need to tap the hole out to next size.

[HS]

It can be saved but you will most likely need to go up a bolt size. Where the ally has been drilled, is there any of the bolt thread left?
What I would do here (and have done in the past) is carefully file down what is left of the bolt (at about 1 o'clock in the pic) until just before the thread is reached. You can then, using a strong pick of some sort, pull/pry the remains of the bolt thread away from the ally thread. Depending on how deep you went into the ally thread you may need to tap the hole out to next size.

Thanks for the response, krusty.  I'm afraid there may be bolt thread left and I may, in effect, have staked the stub of the bolt...not positive.  I had an extractor (relatively thin one but of hardened steel) in there good and the remains of the bolt refused to give.  So when I tried backing out the extractor, the tip gave...I clearly put too much torque on it in hopes of backing out the bolt.

Man I'm pissed at myself right now. 

Sam

[tomkimberly]

Try a left hand drill, most of the time the screw will just spin out.
Tom

[HS]

Try a left hand drill, most of the time the screw will just spin out.
Tom

I don't have one, but I will tomorrow.  Smart.  Thank you.

Sam

[Stev-o]

If it was tough coming out, there may have been an issue previous.

I'd just replace it the lower...


  http://www.ebay.com/itm/Right-Front-Fork-Honda-CB550-CB500-/290846635766?pt=Motorcycles_Parts_Accessories&hash=item43b7cf76f6&vxp=mtr

[strynboen]

drill the rest parts aut..and cut 8 mm threds..

[Lost and Confused]

Have a set of lowers from 79 750. You can have them free, just shipping.



Bob

[HS]

If it was tough coming out, there may have been an issue previous.

I'd just replace it the lower...


  http://www.ebay.com/itm/Right-Front-Fork-Honda-CB550-CB500-/290846635766?pt=Motorcycles_Parts_Accessories&hash=item43b7cf76f6&vxp=mtr

Thanks, Stev-o.  If not joy I might end up with a replacement fork.  I hate the idea of it after going through the sanding and polishing yesterday but it is what it is.

Sam

[HS]

drill the rest parts aut..and cut 8 mm threds..

Thanks, strynboen.  I'm working on that.  I managed to lose the tip of a hardened extractor in there and my bits are obviously crap.  I'll keep working it today and see if I cant get through and the retap it.  I'll need a proper length bolt, perhaps need to cut one to length. 

Sam

[HS]

Have a set of lowers from 79 750. You can have them free, just shipping.



Bob

That's very kind of you, Bob....thanks.  If I get in a pinch, I'll reach out.  I'm hoping I can salvage the fork leg, but with my hands it's 50/50 at best...LOL.

Sam

[Stev-o]

drill the rest parts aut..and cut 8 mm threds..

I managed to lose the tip of a hardened extractor in there...

Extractors are made of hardened steel, will be very difficult to drill. 
FYI - once an easy out is broken in a part, I draw the line on trying to repair.

[HS]

drill the rest parts aut..and cut 8 mm threds..

I managed to lose the tip of a hardened extractor in there...

Extractors are made of hardened steel, will be very difficult to drill. 
FYI - once an easy out is broken in a part, I draw the line on trying to repair.

I FUBAR'd it, Stev-o.  It'll take carbide bit if at all.  We'll see what the day brings.  Man...

Sam

[Stev-o]

drill the rest parts aut..and cut 8 mm threds..

I managed to lose the tip of a hardened extractor in there...

Extractors are made of hardened steel, will be very difficult to drill. 
FYI - once an easy out is broken in a part, I draw the line on trying to repair.

I FUBAR'd it, Stev-o.  It'll take carbide bit if at all.  We'll see what the day brings.  Man...

Sam

Dont let it get you down, this #$%*e happens when working on 35+ year old bikes.
Knowing the next step to move forward makes a good mechanic.

On a side note, I stripped the damn hard brake line in my K4 caliper yesterday.
What to do?!

[HS]

drill the rest parts aut..and cut 8 mm threds..

I managed to lose the tip of a hardened extractor in there...

Sorry to hear that, Stev-o. 

You were right about the hardened steel....FUBAR.  Screw it...time to move on.

Sam

Extractors are made of hardened steel, will be very difficult to drill. 
FYI - once an easy out is broken in a part, I draw the line on trying to repair.

I FUBAR'd it, Stev-o.  It'll take carbide bit if at all.  We'll see what the day brings.  Man...

Sam

Dont let it get you down, this #$%*e happens when working on 35+ year old bikes.
Knowing the next step to move forward makes a good mechanic.

On a side note, I stripped the damn hard brake line in my K4 caliper yesterday.
What to do?!

[madmtnmotors]

With a broken piece of hardened tool steel in there (I've broken both extractors and a taps before) the only way I've been able to clear the hole is with a Dremel and a set of diamond stones. I've also been able to correct an off-center pilot this way as well...


http://www.harborfreight.com/20-piece-18-shank-rotary-diamond-point-tips-69653.html


Plenty of patience too.

[HS]

With a broken piece of hardened tool steel in there (I've broken both extractors and a taps before) the only way I've been able to clear the hole is with a Dremel and a set of diamond stones. I've also been able to correct an off-center pilot this way as well...


http://www.harborfreight.com/20-piece-18-shank-rotary-diamond-point-tips-69653.html


Plenty of patience too.

That's good info there, mad.  Thanks for sharing.

Sam