Home |
Search |
Today's Posts |
|
Metalworking (rec.crafts.metalworking) Discuss various aspects of working with metal, such as machining, welding, metal joining, screwing, casting, hardening/tempering, blacksmithing/forging, spinning and hammer work, sheet metal work. |
Reply |
|
LinkBack | Thread Tools | Display Modes |
#1
Posted to rec.crafts.metalworking
|
|||
|
|||
Broken allen wrench removal
A friend of mine (really!) went to remove a mirror
from his motorcycle. The mirror mount is steel and mounts to the front brake master cylinder (aluminum). There is a recess in the mirror into which an allen head bolt holds the mirror to the master cylinder. He broke the allen wrench flush to the top of the bolt. The head of the bolt is recessed to where you can't get at the sides of it. The bottom of the bolt is visible on the underside of the master cylinder. The only way I can think of to fix this is to take the master cylinder off, turn it upside down. Then drill through the bolt from the bottom side. Then take a punch and knock out the allen wrench. Then use an impact to take the bolt out. We'd have to fill the master cylinder full first so air doesn't get into the line when flipping it over. This sounds like a lot of work. Anyone have any easier suggestions? His original problem is the mirror keeps loosening up on the 'stalk'. The ball on the 'stalk' is ridged. That sits in a plastic piece. By moving the mirror you can see where the plastic is falling apart in the ridges. He's already replaced the mirror several times. Is there any kind of goop that could be put in there which would hold the mirror, but still allow movement? Wayne D. |
#2
Posted to rec.crafts.metalworking
|
|||
|
|||
Broken allen wrench removal
Wayne wrote:
A friend of mine (really!) went to remove a mirror from his motorcycle. The mirror mount is steel and mounts to the front brake master cylinder (aluminum). There is a recess in the mirror into which an allen head bolt holds the mirror to the master cylinder. He broke the allen wrench flush to the top of the bolt. The head of the bolt is recessed to where you can't get at the sides of it. The bottom of the bolt is visible on the underside of the master cylinder. The only way I can think of to fix this is to take the master cylinder off, turn it upside down. Then drill through the bolt from the bottom side. Then take a punch and knock out the allen wrench. Then use an impact to take the bolt out. We'd have to fill the master cylinder full first so air doesn't get into the line when flipping it over. This sounds like a lot of work. Anyone have any easier suggestions? His original problem is the mirror keeps loosening up on the 'stalk'. The ball on the 'stalk' is ridged. That sits in a plastic piece. By moving the mirror you can see where the plastic is falling apart in the ridges. He's already replaced the mirror several times. Is there any kind of goop that could be put in there which would hold the mirror, but still allow movement? Wayne D. I don't see where you have anything to lose by trying your favorite real penetrating oil, a couple of gentle heat cycles, a left-handed drill bit from the top (or remove the master cylinder and use a RH drill from the bottom) and try an easy-out. Another trick I like is to make a little square of sheet metal about the size of a postage stamp, punch a hole in the center, and plug weld it to the end of the bolt (using O/A or MIG or however you can) then welding a nut to the sheet metal and using the nut to turn out the bolt. Might be tricky with the seals in the master cylinder so close, though. Steel bolts frozen to aluminum can be very tough indeed. My guess is you'll wind up using a helicoil or equivalent, or maybe buying a new master cylinder. My guess is this motorcycle isn't a BMW. GWE |
#3
Posted to rec.crafts.metalworking
|
|||
|
|||
Broken allen wrench removal
If it was the proper size Allen, it will come loose with a couple of taps
back, the opposite direction from which it broke, if it was a SAE jammed into a Metric bolt, good luck. If it snapped and didn't twist, it going to be hard. Good Luck gary "Wayne" wrote in message news A friend of mine (really!) went to remove a mirror from his motorcycle. The mirror mount is steel and mounts to the front brake master cylinder (aluminum). There is a recess in the mirror into which an allen head bolt holds the mirror to the master cylinder. He broke the allen wrench flush to the top of the bolt. The head of the bolt is recessed to where you can't get at the sides of it. The bottom of the bolt is visible on the underside of the master cylinder. The only way I can think of to fix this is to take the master cylinder off, turn it upside down. Then drill through the bolt from the bottom side. Then take a punch and knock out the allen wrench. Then use an impact to take the bolt out. We'd have to fill the master cylinder full first so air doesn't get into the line when flipping it over. This sounds like a lot of work. Anyone have any easier suggestions? His original problem is the mirror keeps loosening up on the 'stalk'. The ball on the 'stalk' is ridged. That sits in a plastic piece. By moving the mirror you can see where the plastic is falling apart in the ridges. He's already replaced the mirror several times. Is there any kind of goop that could be put in there which would hold the mirror, but still allow movement? Wayne D. |
#4
Posted to rec.crafts.metalworking
|
|||
|
|||
Broken allen wrench removal
On Tue, 11 Apr 2006 17:13:39 -0500, Wayne
wrote: A friend of mine (really!) went to remove a mirror from his motorcycle. The mirror mount is steel and mounts to the front brake master cylinder (aluminum). There is a recess in the mirror into which an allen head bolt holds the mirror to the master cylinder. He broke the allen wrench flush to the top of the bolt. The head of the bolt is recessed to where you can't get at the sides of it. The bottom of the bolt is visible on the underside of the master cylinder. The only way I can think of to fix this is to take the master cylinder off, turn it upside down. Then drill through the bolt from the bottom side. Then take a punch and knock out the allen wrench. Then use an impact to take the bolt out. We'd have to fill the master cylinder full first so air doesn't get into the line when flipping it over. This sounds like a lot of work. Anyone have any easier suggestions? His original problem is the mirror keeps loosening up on the 'stalk'. The ball on the 'stalk' is ridged. That sits in a plastic piece. By moving the mirror you can see where the plastic is falling apart in the ridges. He's already replaced the mirror several times. Is there any kind of goop that could be put in there which would hold the mirror, but still allow movement? Wayne D. As far as the wrench goes I can think of two things. First, use a punch to mark the center of the wrench. Banging on it may loosen it. After using the punch drill a hole that's the tap drill size for a thread size smaller than the wrench, but not by much. Tap the wrench stub. Even though the wrench stub is hard, a tap is harder. The tapping process will probably loosen the wrench stub if the drilling doesn't. Or, after drilling the hole, use an impact screwdriver with a phillips bit in the hole. Impact screwdrivers, the kind you hit with a hammer, can be had pretty cheap, like 10 bucks. If you already have the impact wrench, and it sounds from your post that you do, then you're set. Before using the impact wrench on the screw itself maybe a little oil and heat could be used first. I think drilling from the back side is way too much work. I bet that wrench stub pops out when you start to work on it. ERS |
#5
Posted to rec.crafts.metalworking
|
|||
|
|||
Broken allen wrench removal
In article , Wayne says...
times. Is there any kind of goop that could be put in there which would hold the mirror, but still allow movement? Yes. A Napolean bar end mirror. Throw the stock ones away. Jim -- ================================================== please reply to: JRR(zero) at pkmfgvm4 (dot) vnet (dot) ibm (dot) com ================================================== |
#6
Posted to rec.crafts.metalworking
|
|||
|
|||
Broken allen wrench removal
Oops, I didn't notice it's the wrench and not the bolt that sheared. In that
case, I suggest you drill a hole down the center of the top of the wrench, tap it, and run a long screw through it to bear on the bolt and push out the wrench stub. Or just freeze a welding rod to it and pull. GWE Wayne wrote: A friend of mine (really!) went to remove a mirror from his motorcycle. The mirror mount is steel and mounts to the front brake master cylinder (aluminum). There is a recess in the mirror into which an allen head bolt holds the mirror to the master cylinder. He broke the allen wrench flush to the top of the bolt. The head of the bolt is recessed to where you can't get at the sides of it. The bottom of the bolt is visible on the underside of the master cylinder. The only way I can think of to fix this is to take the master cylinder off, turn it upside down. Then drill through the bolt from the bottom side. Then take a punch and knock out the allen wrench. Then use an impact to take the bolt out. We'd have to fill the master cylinder full first so air doesn't get into the line when flipping it over. This sounds like a lot of work. Anyone have any easier suggestions? His original problem is the mirror keeps loosening up on the 'stalk'. The ball on the 'stalk' is ridged. That sits in a plastic piece. By moving the mirror you can see where the plastic is falling apart in the ridges. He's already replaced the mirror several times. Is there any kind of goop that could be put in there which would hold the mirror, but still allow movement? Wayne D. |
#7
Posted to rec.crafts.metalworking
|
|||
|
|||
Broken allen wrench removal
HOw about penetrating oil and a BIG magnet the allen key SHOULD be a
magnetic family of steel right? On Tue, 11 Apr 2006 17:13:39 -0500, Wayne wrote: A friend of mine (really!) went to remove a mirror from his motorcycle. The mirror mount is steel and mounts to the front brake master cylinder (aluminum). There is a recess in the mirror into which an allen head bolt holds the mirror to the master cylinder. He broke the allen wrench flush to the top of the bolt. The head of the bolt is recessed to where you can't get at the sides of it. The bottom of the bolt is visible on the underside of the master cylinder. The only way I can think of to fix this is to take the master cylinder off, turn it upside down. Then drill through the bolt from the bottom side. Then take a punch and knock out the allen wrench. Then use an impact to take the bolt out. We'd have to fill the master cylinder full first so air doesn't get into the line when flipping it over. This sounds like a lot of work. Anyone have any easier suggestions? His original problem is the mirror keeps loosening up on the 'stalk'. The ball on the 'stalk' is ridged. That sits in a plastic piece. By moving the mirror you can see where the plastic is falling apart in the ridges. He's already replaced the mirror several times. Is there any kind of goop that could be put in there which would hold the mirror, but still allow movement? Wayne D. |
#8
Posted to rec.crafts.metalworking
|
|||
|
|||
Broken allen wrench removal
Wayne wrote: A friend of mine (really!) went to remove a mirror from his motorcycle. The mirror mount is steel and mounts to the front brake master cylinder (aluminum). There is a recess in the mirror into which an allen head bolt holds the mirror to the master cylinder. He broke the allen wrench flush to the top of the bolt. The head of the bolt is recessed to where you can't get at the sides of it. The bottom of the bolt is visible on the underside of the master cylinder. The only way I can think of to fix this is to take the master cylinder off, turn it upside down. Then drill through the bolt from the bottom side. Then take a punch and knock out the allen wrench. Then use an impact to take the bolt out. We'd have to fill the master cylinder full first so air doesn't get into the line when flipping it over. This sounds like a lot of work. Anyone have any easier suggestions? His original problem is the mirror keeps loosening up on the 'stalk'. The ball on the 'stalk' is ridged. That sits in a plastic piece. By moving the mirror you can see where the plastic is falling apart in the ridges. He's already replaced the mirror several times. Is there any kind of goop that could be put in there which would hold the mirror, but still allow movement? Wayne D. If you are able to drill the Allen wrench, you might be able to get it out by packing the hole with grease, inserting a close fitting pin punch, and hitting it with a hammer. John Martin |
Reply |
Thread Tools | Search this Thread |
Display Modes | |
|
|
Similar Threads | ||||
Thread | Forum | |||
How to clean up broken glass in a dish-washer | Home Repair | |||
How to clean up broken glass in a dish-washer | Home Ownership | |||
Craftsman tools not warranted/guaranteed forever | Metalworking | |||
help needed with broken crt neck pcb | Electronics Repair | |||
FA: Broken PIONEER DVL-V888 Laserdisc DVD / Broken sharp VL-H860U Hi8camcorder w/ LCD Screen | Electronics Repair |