Wheel repair; Dumb idea?

[Lynn]

Dumb idea?

Old school American Racing Torque Thrust wheels on the 57.

9 or 10 of the screws holding on the spinners were broken off in the wheels. I got all of them out on three of the wheels. The fourth wheel still has three broken screws (8 x 32) that I cannot get out.

I used a “rescue bit” on most of the others. But, I am afraid my small rescue bit is now worn out. Rescue bits are not drill bits, but more like little bitty rotary files that cut through almost anything.... until they wear out. I used one to chip out an easy out and a broken drill bit from an old exhaust manifold off my brother’s MG a few years ago. But alas, I think I finally wore it out. They are really expensive ($150 bucks for a set of three if I remember correctly).

Thinking I will affix this last wheel to the drill press, then drill around the three broken screws with a 5/16 hole saw bit. After removing the core, I can tap for a 3/8 standard thread bolt. Will fill the hole with a hardware grade 3/8 bolt, cut it off close to flush, then grind it smooth with the surface of the wheel, then drill and tap for an 8 x 32 screw.

The larger bolt will be completely hidden by the flange on the spinner.

Dumb idea?

[jer]

I"d feel good about that. Some guys put plastic inserts in there and they seem to hold fine.

[SuperNovaSS]

There is an acid kit you can buy that will react with the steel but not the aluminum. You build a dam out of clay around the hole with the broken bolt and put the acid it. I used it on a weber carb year ago with good results.


Jason

[hiperf69]

Lynn,
#1 take the insert your going to use,trim to length you need, and drill and tap the 8-32
thread and use a longer 8-32 bolt with a jam nut to drive the
Insert into the wheel
Or
#2 go to the hardware store and pick up a 8-32 Heli-coil kit
an just insert the threaded insert
Or
#3 Throw the wheel in a box, ship to me, and I will put up in the Bridgeport
Fix it and ship it back!
Joe

[1967 4K]

Joe’s idea #2 or 3.

[Too Many Projects]

Since the rescue bit worked so well, for a long time, the easy route would be to purchase another one and have it for "the next time".

Aside from that, I'd drill the broken screw out and heli-coil the hole or just tap for the next larger fastener, 10 or 12-32, or use the plastic insert idea.

Drilling the hole oversize, tapping that hole to insert a larger bolt and then drill and tap the bolt for the screw seems like a lot more work.
But we all get cheap and over analyze a simple problem now and then......

[big gear head]

After many failed attempts at using a drill and ez out I no longer do it that way. I've been using a welder to remove broken bolts for about 40 years and it works just about every time. Put a washer over the broken bolt and weld them together. Then put a nut on the washer and weld them together. Turn the nut and the bolt comes out.

[hiperf69]

After sleeping on this over night,since you have 3 still holding the cap on I think I would
cut the heads off and epoxy the heads to the cap and not think about it.

Freddie’s idea also works great if it’s steel in steel but, steel screws in aluminum will cook the wheel especially trying to weld a small 8-32 screw. And if the wheel is MAGNESIUM
you could lose the wheel in the fire, along with the garage, the neighbors garage your house and everything on the block.
Just a little morning humor.Joe

[scuncio]

I have done a lot of these with varying degrees of success. Now I just use my Bridgeport and install a helicoil. Happy to do that for you if you like. Alternatively, I machined a drill jig that you can borrow that guides the drill bit, but you may still break bits trying to get those hardened screws out.