Re: Well, looks like my ''good luck'' ended..
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I had a thought last night.
Would it be possible to enlarge the opening around, what remains,, of the bolt?
Is there plenty of metal to do so, and no passageways that you would cut into ?
I'm thinking, to about,, 14mm. (or whatever is needed, to do the job)
If we can do that,,, then we could have a tube machined to the proper length, say about 35 mm or so long.
Have it threaded on the inside.
Using a bolt and a few nuts, (locked in the top of our part) run it down on the exposed stud until it seats at the bottom.
Remove bolt and nuts. Now,,, run shorter new bolt into this, to hold down new injector..
I was thinking about using a small hole saw like tool to remove the metal from the head.
Possible ? or bad idea?
Or,,, having not actually seen it.
Is there any exposed thread already?
Enough to do this without,, removing any aluminum ?
im not really understanding what you mean, but. if the broken bolt is 35mm (about 1 3/8" down into the hole) what if the exposed hole was enlarged and had a threaded insert installed (not a heli coil). you could then use a bolt that would be about 1 3/8" or shorter to hold the injector hold down in place. if you need a insert made let me know and ill whip you one out and mail it to you. i would just need the dimensions.
PS: DO NOT USE A HOLE SAW! it would be best to use a hand reamer to enlarge the hole slowly in steps. that way the hole will be round and straight. example: 7mm reamer, 8mm reamer, 9mm reamer etc etc until you get to the finished tap size. then tap the hole to match the threaded insert O.D.
if the mechanic uses a air or electric drill he may gaul the drill bit into the aluminum and break it off (bad bad bad), drill it on an angle, or make the hole out of round. It would be best to use a hand reamer and go slowly in steps, and use a cutting fluid like tap magic or kerosen.