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Replacing rusty insert fasteners

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JSharp

10-02-2007 05:49:08




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Has anyone got any tips for drilling out or otherwise removing rusty fasteners? I have a few #10 fasteners that are rusted solid and broken off almost flush in their threaded panel inserts.
I was going to just drill them out and retap the insert but of course the rusty fastener is many times harder than the surrounding insert. The drill just walks out into the soft metal of the insert.

And the IH inserts are large and welded to the panel making replacement of them non-trivial.
Any ideas?

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JSharp

10-05-2007 11:25:03




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 Re: Replacing rusty insert fasteners in reply to JSharp, 10-02-2007 05:49:08  
I ground the inserts down to 1/2 thickness with a hand grinder and ground the remaining part of the old screws out with a small stone on a Dremel. Then I tack welded square nuts on the back with .023" wire in my Mig.

Believe it or not, I thought of the Edm solution early on. But the only shop I know of in the area that has one would want $ to do it, and one of the parts is too large for their machine anyway. This was free other than the time it took. Thankfully there were only 2.

Oh well, it's not "correct" anymore but the fasteners are in and secure. And anyone looking behind the dash to check for such things seriously needs to get a life...third party image

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slowfolk

10-05-2007 06:53:52




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 Re: Replacing rusty insert fasteners in reply to JSharp, 10-02-2007 05:49:08  
If you can get the part with the broken fastner to a machine shop that has an EDM Machine they can burn out the fastner with a new like hole.

Slowfolk



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JSharp

10-02-2007 09:52:46




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 Re: Replacing rusty insert fasteners in reply to JSharp, 10-02-2007 05:49:08  
I had it clamped down in the drill press. The trouble is the rusted screw is so hard and the drill is so small it walks. It's #25 drill. I probably should have tried a center drill first but I don't have any that small.

I'm going to attack it with a Dremel stone tonight if I can't come up with a better plan. I suppose if nothing else once I get a through hole of clearance size I can tack weld another nut behind it...

Anyone else notice that fixing the really small things on these old tractors takes the most time? third party image

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soundguy

10-03-2007 07:51:12




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 Re: Replacing rusty insert fasteners in reply to JSharp, 10-02-2007 09:52:46  
The 'devil' is always in the 'details'

Soundguy



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soundguy

10-02-2007 08:45:35




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 Re: Replacing rusty insert fasteners in reply to JSharp, 10-02-2007 05:49:08  
Any way to get the part to a drillpress to keep it from walking?

If not have you tried a dremil type abrasive bit?

Soundguy



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