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Tool Talk Discussion Forum

Setscrew Problem

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Rod (NH)

09-01-2006 18:35:12




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I have a hub that is attached to a 1-1/2" shaft using a 3/8" hex drive setscrew. After many years of outside exposure, the setscrew is rusted in place. After liberal applications of PB Blaster and mild impacting with a 3/8 drive impact wrench and hex driver, it doesn't want to budge. The setscrew is set flush with the hub outside diameter. Any thoughts on how to get this out? I thought about cutting it out with an oxy/acet torch but I really don't want to damage the hub too much. Anyone tried drilling one of these hardened setscrews out? Think it's possible to draw the temper with the torch and then drill out with a standard HS steel drill? I can always helicoil the hub for a new setscrew if necessary. Other suggestions?

Thanks, Rod

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`Bernie in MA

09-03-2006 06:42:14




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 Re: Setscrew Problem in reply to Rod (NH), 09-01-2006 18:35:12  
I had to get a cast iron flat pulley off a baler engine shaft. The top of the allen setscrew was broken off. I used a small holesaw. Took the pilot drill out after I drilled a piece of scrap, clamped the scrap to the pulley for a guide and sawed down to the shaft. Could have reused the pulley by tapping for a bigger screw.



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Rod (NH)

09-02-2006 09:05:15




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 Thanks all... in reply to Rod (NH), 09-01-2006 18:35:12  
All great ideas but Wayne's was the one that saved the day. I never would have thought of a masonry bit. I simply drilled the entire setscrew out. It worked slick. Then with some heat and a puller, the hub came right off. Now a helicoil in the hub for a new setscrew and I'm back in business. A tip to remember.

Rod



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MarkB_MI

09-03-2006 08:22:26




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 Re: Thanks all... in reply to Rod (NH), 09-02-2006 09:05:15  
Thanks for posting your results. It's nice to know what the solution was to a problem.

Too often someone will post a problem, get a bunch of responses then doesn't respond to say what was the end result.



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Vern-MI

09-02-2006 05:02:00




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 Re: Setscrew Problem in reply to Rod (NH), 09-01-2006 18:35:12  
Try using a punch that fits right down through the hex drive on the set screw. Give it a few wacks and see if that breaks the rust and releases the compression of the screw on the shaft.



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MI mark

09-01-2006 22:07:26




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 Re: Setscrew Problem in reply to Rod (NH), 09-01-2006 18:35:12  
if that is a cast iron hub you'll have to be carefull of cracking it but that also makes it easier to get out too as you can prbably use a brazing tip to heat it and keep the heat down on the hub if it's a steel hub and shaft heat the screw and hub up so the screw and hub are red hot and stick it in a pail of water till cool then just unscrew it a hose will not work i've tried that the pail will though .

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NC Wayne

09-01-2006 20:50:08




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 Re: Setscrew Problem in reply to Rod (NH), 09-01-2006 18:35:12  
Your right you probably aren't gonna be able to drill it with a "regular" drill bit but you can do it with carbide. You can get a carbide tipped masonary bit (not a hammer drill bit, their ground completely wrong) from just about anywhere and drill it that way. If it's a larger bit you may have to grind the carbide a little to get the proper relief on the cutting edge, that kinds varies with the different mfgs, but typically the smaller bits are close enough to work right out of the pack. The main thing is on a masonary bit the carbide is in the form of inserts that have been brazed in so you have to use plenty of cutting oil or other coolant to keep the temps low enough so that the carbide doesn't come out. Once you get a hole through it then try the heating and qenching trick and it should draw enough to loosen it. I've been doing mechanic work all of my life and this is one of the first tricks my Dad taught me about getting out hardened bolts that had broken. I got two 3/8 hardened bolts, that someone else had totally massacared, out of an Onan block the other night using a 5/32 Blu-Mol bit, right out of the pack, from Home Depot. Took the whole pack of 5 to get holes through both pieces, which were nearly 3/4 long, but it beat the heck out of the customer having to buy a new engine or block. Hope this helps.

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XRogerX

09-02-2006 15:23:28




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 Re: Setscrew Problem in reply to NC Wayne, 09-01-2006 20:50:08  
I have also used this trick to drill reed valve material.



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old

09-01-2006 18:41:36




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 Re: Setscrew Problem in reply to Rod (NH), 09-01-2006 18:35:12  
Shoot heat it up real good and then cool it with wax or PB. Then when its cooled down good give it a try. It may take a few tries doing it that way but if you do it a few times it will probably give up



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