fixing a sheared off bolt in aluminum


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virgilmobile
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fixing a sheared off bolt in aluminum

Postby virgilmobile » Thu May 17, 2012 6:07 pm



I had to try this idea...
A bolt sheared off on a master cylinder,the one I tried on is a scrap one.The bolt cannot be removed and taping wont work.
Here's my solution....Remember,I'm not a machinist but I've got a drill and some hand tools.,so here goes.
Sheared off bolt
Sheared off bolt
drilled a 1/8" pilot hole
drilled a 1/8" pilot hole
drilled a bigger hole..too big to tap
drilled a bigger hole..too big to tap
this is just too big.a new bolt won't fit through the resavoyer
this is just too big.a new bolt won't fit through the resavoyer
ground down the side of a nut to the same size as a bit I had
ground down the side of a nut to the same size as a bit I had
counter sunk the hole deep enough to recess the nut
counter sunk the hole deep enough to recess the nut
tapped it into place
tapped it into place
peened around the nut to secure it in the casting
peened around the nut to secure it in the casting
looks good
looks good
lined up just right
lined up just right
It took 30 minutes to drill it out and fit the ground nut in place.Plenty enough to hold it there
It took 30 minutes to drill it out and fit the ground nut in place.Plenty enough to hold it there

I did this just to see if it was a viable solution.It seems to be fine and may help salvage a difficult part to find.It was also less time consuming than waiting for a E-Bay order to arrive.



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thrasherg
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Re: fixing a sheared off bolt in aluminum

Postby thrasherg » Thu May 17, 2012 6:45 pm

I would have fitted a heli coil or time sert, as it would be a stronger fix, but you made a tidy job of that!! :)

Gary

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virgilmobile
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Re: fixing a sheared off bolt in aluminum

Postby virgilmobile » Thu May 17, 2012 7:05 pm

I thought of that but I don't have a kit that would have those sizes and bit,and NAPA is expensive for the whole thing.
This is a repair that can be done cheap, quick and can get you back on the road in a few hours.
Obviously it isn't designed to lift a engine with but is plenty enough to hold on a piece of plastic or cover.

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seabee_
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Re: fixing a sheared off bolt in aluminum

Postby seabee_ » Thu May 17, 2012 11:34 pm

That's a good idea Virgil. I would suggest putting a small dab of epoxy around the sides to help hold the nut in place. You would just have to be careful not to get the epoxy in the thread area.
Paul
CE1 Navy Seabees/RET
1981 to 2002
ASE Mechanic

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virgilmobile
Posts: 7649
Joined: Sun Sep 19, 2010 5:39 pm
Location: Denham Springs,La.
Motorcycle: 1988 GL1500 I
Previously owned
78 GL1000
81 GL1100
82 GL1100 I
83 GL1100 I
83 GL1100 standard
84 GL 1200 I

Re: fixing a sheared off bolt in aluminum

Postby virgilmobile » Fri May 18, 2012 7:33 am

No epoxy needed.the insert is resesed into the casting 1/16" and peened around it's edge.you'd break the plastic before the insert would rip out of the casting.




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