Technical Head stud hole from Hell. Let's make it serviceable!

Carrying on from the previous video I tackle a head stud hole that went badly out of position after a previously botched repair. I manage to botch it on my first attempt at fixing it, but do eventually get it into a good useable condition. I hope you find it interesting.

 

For the next time.

 

Great video. Once again, Mart brings one back.

 

Mart - Knowing how much rework was needed with this repair, would you approach the next repair with a much larger plug? A plug that would allow centering a new hole completely in the new material instead of offset into the parent material. I realize the casting would have its limits along with your tooling capability. How big of a hole could you drill and tap without needing outside shop ***istance?

 

Nice save Mart!
Jim

 

great job Mart keep it up RLS

 

Well done!

 

Hello Chris.
"Mart - Knowing how much rework was needed with this repair, would you approach the next repair with a much larger plug? A plug that would allow centering a new hole completely in the new material instead of offset into the parent material."
No. The deck face has bosses cast around where the stud holes go. The material is thicker there. So it would be detrimental to stray outside the immediate area and out into the thin, non-reinforced deck area.
I'm not an expert and am self taught. When you watch my videos more often than not I am learning a lesson while doing the job.
The lesson learnt on this one would be to go to extra lengths to locate the drill on centre and ensure it (or a milling cutter) is sufficiently guided to keep it on centre, or at least minimise the tendency to try to wander.

 

Mart,
You did good,,,,,,but he was right,,,,,you should have started with a plug at the beginning .
After plugging the hole and filing it flush,,,,,,you could put the head on the deck and line up all the bolts .
Then insert a transfer punch in the open bolt hole to center the hole ,,,,drill,,,,,then re tap to size .
It works great,,,,,easy to plug holes and redrill on location .
You still did good,,,,it took a fair amount of extra work,,,,,but you got it pretty darn close at the end .
Good job !

Tommy

 

Thanks for the insight, Mart. I didn’t realize the thickness varied in the deck. Ugh! That really does make things more difficult!

I do enjoy your “learn as you go”approach to your videos -along with the difficulties and failures! Even my best planned projects invariably end in disaster, failure or a “I don’t like how that looks”!