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Hi,
This might sound a bit basic but it has stumped me! While drilling on
my lathe, I have broken two 2mm drills in two separate holes in a
steam engine alluminium casting. They have both broken off flush so
there is nothing to get hold of and there is not a lot of space
around them. I have thought of over-drilling the whole lot out (if I
can) and making a screw-in plug and milling it flush.

Is the casting a write-off - Or is there another way?

All help appreciated
Regards
Ken

--- In 7x12minilathe@y..., "Capt Ken Appleby" <captkenn@m...> wrote:

Hi,
This might sound a bit basic but it has stumped me! While drilling

on

my lathe, I have broken two 2mm drills in two separate holes in a

Is the casting a write-off - Or is there another way?

Someone on the 7X10 minilathe group gave a reference to a site where
it was stated that you can put an aluminum part in simmering water
that is saturated with alum, (of the kind used for making pickles,
(potassium alum?)), and the tap will begin to bubble a bit, when the
bubbling stops, the tap is dissolved.

You might want to ask this same question there and get the referenced
site.



Al

--- In 7x12minilathe@y..., "Capt Ken Appleby" <captkenn@m...> wrote:

Hi,
This might sound a bit basic but it has stumped me! While drilling

on

my lathe, I have broken two 2mm drills in two separate holes in a
steam engine alluminium casting. They have both broken off flush so
there is nothing to get hold of and there is not a lot of space
around them. I have thought of over-drilling the whole lot out (if

I

can) and making a screw-in plug and milling it flush.

Is the casting a write-off - Or is there another way?

All help appreciated
Regards
Ken

Check this link,

Al

try filling the hole with penetrating oil and leaving it to soak. they may
pull out with pliers
DAVID WILLIAMS
BOLTON
ENGLAND
davidalan@...
SAM ZERO

Hi Ken:

I hate it when that happens...I find that deeper holes in aluminum
need to be cleaned out more so they won't bind 'cause it's gummy
stuff. Try putting the workpiece in a vise and tapping the bit with
a hammer and small drift. Sometimes just working it in different
directions will loosen it off.

mike




--- In 7x12minilathe@y..., "Capt Ken Appleby" <captkenn@m...> wrote:

Hi,
This might sound a bit basic but it has stumped me! While drilling

on

my lathe, I have broken two 2mm drills in two separate holes in a
steam engine alluminium casting. They have both broken off flush so
there is nothing to get hold of and there is not a lot of space
around them. I have thought of over-drilling the whole lot out (if

I

can) and making a screw-in plug and milling it flush.

Is the casting a write-off - Or is there another way?

All help appreciated
Regards
Ken

--- In 7x12minilathe@..., "Capt Ken Appleby"
<captkenn@...> wrote:

Hi,
This might sound a bit basic but it has stumped me! While drilling

on

my lathe, I have broken two 2mm drills in two separate holes in a
steam engine alluminium casting. They have both broken off flush so
there is nothing to get hold of and there is not a lot of space
around them. I have thought of over-drilling the whole lot out (if I
can) and making a screw-in plug and milling it flush.

Is the casting a write-off - Or is there another way?

All help appreciated
Regards
Ken

Hi,
When drilling aluminium a good cutting fluid is a must, this kind of
metal welds to the drill bit quick.

Interesting, a 2002 msg has resurfaced!

For something that small, the most reliable way to get the broken
drills out is chemically. Aluminum is pretty much non-reactive to
acids, steel is reactive. Thus, the classic approach of dissolving
the broken tool out with a strong, hot alum solution. Swimming
pool/Spa & garden supply places sell alum for lowering pH.

Roy

--- In 7x12minilathe@..., "machinest80" <machinest80@...>
wrote:

--- In 7x12minilathe@..., "Capt Ken Appleby"
<captkenn@> wrote:

Hi,
This might sound a bit basic but it has stumped me! While

drilling

on

my lathe, I have broken two 2mm drills in two separate holes in a
steam engine alluminium casting. They have both broken off flush

so

there is nothing to get hold of and there is not a lot of space
around them. I have thought of over-drilling the whole lot out

(if I

can) and making a screw-in plug and milling it flush.

Is the casting a write-off - Or is there another way?

All help appreciated
Regards
Ken

Hi,
When drilling aluminium a good cutting fluid is a must, this kind

of

metal welds to the drill bit quick.

Use Alum to etch them out.


--- machinest80 <machinest80@...> wrote:

--- In 7x12minilathe@..., "Capt Ken
Appleby"
<captkenn@...> wrote:

Hi,
This might sound a bit basic but it has stumped

me! While drilling
on

my lathe, I have broken two 2mm drills in two

separate holes in a

steam engine alluminium casting. They have both

broken off flush so

there is nothing to get hold of and there is not a

lot of space

around them. I have thought of over-drilling the

whole lot out (if I

can) and making a screw-in plug and milling it

flush.

Is the casting a write-off - Or is there another

way?

All help appreciated
Regards
Ken

Hi,
When drilling aluminium a good cutting fluid is a
must, this kind of
metal welds to the drill bit quick.

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Hi Ken,

Someone (possibly on this forum) had a neat idea after breaking the
tip of a centre drill. They re-ground the thicker remaining stub to
gouge AROUND the broke small tip. This allowed access to get hold of
the broken piece to reverse it out.

Is that viable in this case? Maybe use the stub of an old (broken)
drill bit. Needs to be stumpy and solid. Butcher's technique but may
save a casting.

John





--- In 7x12minilathe@..., "machinest80"
<machinest80@...> wrote:

--- In 7x12minilathe@..., "Capt Ken Appleby"
<captkenn@> wrote:

Hi,
This might sound a bit basic but it has stumped me! While

drilling

on

my lathe, I have broken two 2mm drills in two separate holes in

a

steam engine alluminium casting. They have both broken off flush

so

there is nothing to get hold of and there is not a lot of space
around them. I have thought of over-drilling the whole lot out

(if I

can) and making a screw-in plug and milling it flush.

Is the casting a write-off - Or is there another way?

All help appreciated
Regards
Ken

Hi,
When drilling aluminium a good cutting fluid is a must, this kind

of

metal welds to the drill bit quick.

Vicki Ford has a piece on doing this (with photo) on her website. Don't know the link straight off but it is in the links section of www.mini-lathe.com along with some other neat stuff.

Gerry
leeds UK

From: "born4something" <ajs@...>
Reply-To: 7x12minilathe@...
To: 7x12minilathe@...
Subject: [7x12minilathe] Re: Basic problem?
Date: Mon, 19 Mar 2007 10:19:40 -0000

Hi Ken,

Someone (possibly on this forum) had a neat idea after breaking the
tip of a centre drill. They re-ground the thicker remaining stub to
gouge AROUND the broke small tip. This allowed access to get hold of
the broken piece to reverse it out.

Is that viable in this case? Maybe use the stub of an old (broken)
drill bit. Needs to be stumpy and solid. Butcher's technique but may
save a casting.

John





--- In 7x12minilathe@..., "machinest80"
<machinest80@...> wrote:

--- In 7x12minilathe@..., "Capt Ken Appleby"
<captkenn@> wrote:

Hi,
This might sound a bit basic but it has stumped me! While

drilling

on

my lathe, I have broken two 2mm drills in two separate holes in

a

steam engine alluminium casting. They have both broken off flush

so

there is nothing to get hold of and there is not a lot of space
around them. I have thought of over-drilling the whole lot out

(if I

can) and making a screw-in plug and milling it flush.

Is the casting a write-off - Or is there another way?

All help appreciated
Regards
Ken

Hi,
When drilling aluminium a good cutting fluid is a must, this kind

of

metal welds to the drill bit quick.

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by the way broked centre drills can be converted into nice flat bottom drills by grinding the tip square and putting a bit of relief on the citting edges

Gerry
Leeds UK

From: "born4something" <ajs@...>
Reply-To: 7x12minilathe@...
To: 7x12minilathe@...
Subject: [7x12minilathe] Re: Basic problem?
Date: Mon, 19 Mar 2007 10:19:40 -0000

Hi Ken,

Someone (possibly on this forum) had a neat idea after breaking the
tip of a centre drill. They re-ground the thicker remaining stub to
gouge AROUND the broke small tip. This allowed access to get hold of
the broken piece to reverse it out.

Is that viable in this case? Maybe use the stub of an old (broken)
drill bit. Needs to be stumpy and solid. Butcher's technique but may
save a casting.

John





--- In 7x12minilathe@..., "machinest80"
<machinest80@...> wrote:

--- In 7x12minilathe@..., "Capt Ken Appleby"
<captkenn@> wrote:

Hi,
This might sound a bit basic but it has stumped me! While

drilling

on

my lathe, I have broken two 2mm drills in two separate holes in

a

steam engine alluminium casting. They have both broken off flush

so

there is nothing to get hold of and there is not a lot of space
around them. I have thought of over-drilling the whole lot out

(if I

can) and making a screw-in plug and milling it flush.

Is the casting a write-off - Or is there another way?

All help appreciated
Regards
Ken

Hi,
When drilling aluminium a good cutting fluid is a must, this kind

of

metal welds to the drill bit quick.

_________________________________________________________________
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