Goofed, broken drill into workpiece :-((

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Subject Author Date
Goofed, broken drill into workpiece :-(( Steve 03-22-2008
Posted by Andrew Mawson on March 23, 2008, 3:30 pm
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> On Sun, 23 Mar 2008 09:20:41 +0000, Steve wrote:
>
> >
> >>>I've managed, through nothing but carelessness, to break a
1.5mm drill
> >>>bit
> >>>in the cylinder head of the little glow motor I'm (still) making.
Only
> >>>one
> >>>hole left to complete and I broke the soddin' bit into the head.
I've
> >>>been
> >>>dripping sulphuric acid into the hole for the past couple of
days,
> >>>without
> >>>seemingly much progress.
> >>>
> >>>Any better ideas for getting the broken bit out? Is there
anything
> >>>better than H2SO4 to do this job?
> >>>
> >>>I can bodge it , but rather not without trying.
> >>>
>
> Could you use differential expansion to your profit?
> Aluminium has a coeff. of expansion about double that of steel.
Perhaps
> drop the whole bollixed lot into boiling water for a while, lift out
and
> give it a sharp rap.
> Let us know.
> Mike in BC

By far an away the most satisfactory method would be to use EDM. As
it's a small part I would offer that you post it to me, but my machine
is still in storage awaiting completion of the new workshop. There is
bound to be someone local to you who can pop it out in a matter of
minutes on a sinker machine. Look for local diemakers.

AWEM



Posted by Dave Baker on March 23, 2008, 3:50 pm
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>
> By far an away the most satisfactory method would be to use EDM. As
> it's a small part I would offer that you post it to me, but my machine
> is still in storage awaiting completion of the new workshop. There is
> bound to be someone local to you who can pop it out in a matter of
> minutes on a sinker machine. Look for local diemakers.

Oooh, that's handy to know. You have an EDM machine? Not that I've ever
needed the use of one but there's always a first time. What sort of capacity
does it have?
--
Dave Baker
Puma Race Engines



Posted by Andrew Mawson on March 23, 2008, 6:26 pm
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>
message
> >
> > By far an away the most satisfactory method would be to use EDM.
As
> > it's a small part I would offer that you post it to me, but my
machine
> > is still in storage awaiting completion of the new workshop. There
is
> > bound to be someone local to you who can pop it out in a matter of
> > minutes on a sinker machine. Look for local diemakers.
>
> Oooh, that's handy to know. You have an EDM machine? Not that I've
ever
> needed the use of one but there's always a first time. What sort of
capacity
> does it have?
> --
> Dave Baker
> Puma Race Engines
>
>
It's a fairly standard / common Eurospark 425 - iirc takes an
electrode of up to about 10kgs and the tank / table is about 18"
square - hopefully returning to its new home in a few months

AWEM


Posted by Steve on March 23, 2008, 4:12 pm
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>
>> On Sun, 23 Mar 2008 09:20:41 +0000, Steve wrote:
>>
>> >
>> >>>I've managed, through nothing but carelessness, to break a
> 1.5mm drill
>> >>>bit
>> >>>in the cylinder head of the little glow motor I'm (still) making.
> Only
>> >>>one
>> >>>hole left to complete and I broke the soddin' bit into the head.
> I've
>> >>>been
>> >>>dripping sulphuric acid into the hole for the past couple of
> days,
>> >>>without
>> >>>seemingly much progress.
>> >>>
>> >>>Any better ideas for getting the broken bit out? Is there
> anything
>> >>>better than H2SO4 to do this job?
>> >>>
>> >>>I can bodge it , but rather not without trying.
>> >>>
>>
>> Could you use differential expansion to your profit?
>> Aluminium has a coeff. of expansion about double that of steel.
> Perhaps
>> drop the whole bollixed lot into boiling water for a while, lift out
> and
>> give it a sharp rap.
>> Let us know.
>> Mike in BC
>
> By far an away the most satisfactory method would be to use EDM. As
> it's a small part I would offer that you post it to me, but my machine
> is still in storage awaiting completion of the new workshop. There is
> bound to be someone local to you who can pop it out in a matter of
> minutes on a sinker machine. Look for local diemakers.
>
> AWEM
>
>

Thanks for the tip Andrew, I beginning to think it's going to be the only
way.

Steve


Posted by Steve on March 23, 2008, 4:11 pm
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> On Sun, 23 Mar 2008 09:20:41 +0000, Steve wrote:
>
>>
>>>>I've managed, through nothing but carelessness, to break a 1.5mm drill
>>>>bit
>>>>in the cylinder head of the little glow motor I'm (still) making. Only
>>>>one
>>>>hole left to complete and I broke the soddin' bit into the head. I've
>>>>been
>>>>dripping sulphuric acid into the hole for the past couple of days,
>>>>without
>>>>seemingly much progress.
>>>>
>>>>Any better ideas for getting the broken bit out? Is there anything
>>>>better than H2SO4 to do this job?
>>>>
>>>>I can bodge it , but rather not without trying.
>>>>
>
> Could you use differential expansion to your profit?
> Aluminium has a coeff. of expansion about double that of steel. Perhaps
> drop the whole bollixed lot into boiling water for a while, lift out and
> give it a sharp rap.
> Let us know.
> Mike in BC

I diluted the acid as recommended and kept the head warm in the oven most of
the the day, dripping in the acid and prodding at it with a sharp stick
every hour or so. It's still solid though. I don't want to heat the head
too much though.





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