Trickey hole

wrace · 2004-04-08T18:22:41+00:00

Hi folks,I have a questions that you may be able to help me out with. Please look atthis photo: is one of the suspension mounting points on my race car. The holes inthose ears are ~.4760 and I need them to be .5 and with as little"oblonging" of the hole as possible. As you can see there is not a lot ofroom in there to get a drill. The space between the ears is 2.5", the spacebetween the right ear and the frame is 2", and the space between the leftear and the outside frame is 4" (this is larger to facilitate inserting thebolt).I've thought about possibly a right angle drill attachment and a stubby 1/2"drill bit with a small shank. However, the two attachments that I looked atwere to large to fit in that 4" space. What other options are there? I"might" be able to get a 90degree air grinder w/ a grinder/rasp in the 4"space but that would only get the left side ear...Any ideas would be appreciated!Wayne

Apr 08, 2004 21 Replies

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steve walker 22 years ago

I would enlarge the holes and assemble with precision washers on the outer side of each bracket. Then weld the washers in place to the bracket. Don't forget to use shouldered bolts that lock up before squishing the rod end.

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Backlash 22 years ago

3/8" rat tail file slipped through holes, with vise grips clamped at 90 degrees in the middle to serve as a handle. File to fit bolt. Cut file off if it's too long. A 1/2" rat tail file cut off, flats ground, and turned Left handed will also work. This prevents the file from being pulled into the hole and wedging. Turning in this manner will allow it to cut, while constantly pushing itself out of the hole and clearing chips. A rat tail file with the tang ground off and chucked in a drill run in REVERSE makes a wonderful sheet metal reamer. Cuts smooth as butter. I have reamed mis-aligned 3/8" holes through 3" diameter steel male-female shaft assemblies like this, for shear pins.

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