fixing a sheared off bolt in aluminum

[virgilmobile]

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

drilled a 1/8" pilot hole

drilled a bigger hole..too big to tap

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

counter sunk the hole deep enough to recess the nut

tapped it into place

peened around the nut to secure it in the casting

looks good

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

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.

[thrasherg]

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

[virgilmobile]

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.

[seabee_]

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.

[virgilmobile]

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.