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Got Any Tips?? Please share!

Posted: Wed Apr 30, 2014 3:37 pm
by MochetVelo
I was hoping others might have some Brass-Era car restoration tips to share. If you do, please add them to this forum. Photos are helpful. Remember, this forum is for tips rather than questions.These ideas will probably be accessible on this site for years to come, so you may be helping your grandkids when they get their first old car.

Thanks!

Phil
Car Repair Shop.jpg
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Re: Got Any Tips?? Please share!

Posted: Fri May 09, 2014 7:22 pm
by Jugster
1 Hole Jig.jpg
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This is a really neat jig for drilling cotter-pin holes in bolts, but the darned thing costs about fifty bucks, assuming you can find one somewhere. There's a much cheaper albeit less elegant way to put a cotter-pin hole through a bolt that works pretty well—and the most pricey thing you'll have to buy is a really good cobalt drill-bit. Good tools are supposed to be expensive, but this cobalt bit only costs about four bucks—same as a gallon of gas.
2 Irwin Drill Bit.jpg
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The bolt you'll start out with should be about a 5-hardness. That's strong enough without being too hard to drill (We're not working on spacecraft or nuclear subs, here). Of course, buy the correct size castle-nut, but you'll also need two regular hex-nuts.

Stick one of the hex nuts in your vice and use a punch to dent the center of one of the flats.
3 Punch.jpg
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Then, with a regular hand-held drill and that cobalt bit, put a hole though one side of the nut.
4 Hole in Nut.jpg
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If your hole isn't centered perfectly, you have five remaining opportunities on that nut to get it right. You only need one acceptably centered hole.

Measure the spot on the bolt where you want to put the cotter-pin hole and put a dot there with a magic marker.
5 Mark on Bolt.jpg
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Spin the un-drilled hex-nut all the way down the shank of the bolt and then screw on the drilled nut. While looking through the hole in the side of the nut, find the magic marker dot. Now, take out a wrench and use the un-drilled nut as a jam-nut to lock everything in place. Try to get the flats on both hex-nuts to line up.
6 Jam Nut.jpg
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Clamp the stuck-together bolt & nuts unit into your vice, poke your drill-bit through the hole in the side of the nut and drill a little more than halfway through the bolt.
7 Drilling Nut in Vice.jpg
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Unscrew the holed hex-nut, line up the flats on the bolt-head with the flats on the remaining hex nut and clamp the unit in the vice. Poke your drill-bit into the hole in the bolt and drill the rest of the way through.
8 Drilling Bolt in Vice.jpg
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Don't remove the hex-nut just yet. Clean the threads up with a wire brush and then spin the hex-nut up and down the bolt to chase the threads. Take the hex-nut off and finish cleaning up the threads with the wire brush.
9 Wire Brushing Bolt.jpg
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And there you have it: Easy to do, without incurring the cost of a fancy drilling jig.
10 Finished Bolt.jpg
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Re: Got Any Tips?? Please share!

Posted: Sat May 10, 2014 5:30 am
by Rrdoubleday
Great post. Pictures tell the story, good safe way to drill the bolts. Thanks!