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  Topic Review (Newest First)
08-17-2014 05:43 PM
Re: The WTF challenge!

Done something much like this myself recently. Vice grips didn't work, heat didn't work, cutting a slot and using an impact driver didn't work, yelling and screaming didn't work, easyouts didn't work, drilling didn't work (the s/steel just laughed at it's feeble attempt to cut).

...Until I was put on to using a carbide tipped drill bit. These look like masonary bits but are for metal and the like. I was able to drill the remains out by hand with a cordless drill and then I just needed to run a tap through the hole to clean up the thread. The secret to the carbide bit is that it doesn't drift off the hole and cuts like a hot knife through butter. My bolt was threaded into aluminium and the threads were left totally undamaged by the process so easy was it to control.

Sent from my GT-P1000 using Tapatalk 2
08-17-2014 11:29 AM
Re: The WTF challenge!

Originally Posted by JimMcGee View Post
BTW, these problems are always more fun when they're on someone else's boat!

Best of luck and post pics if you can.
thats cruel

but true
08-17-2014 09:51 AM
Re: The WTF challenge!

BTW, these problems are always more fun when they're on someone else's boat!

Best of luck and post pics if you can.
08-17-2014 09:45 AM
Re: The WTF challenge!

SVAuspicious raises a good point.

I was thinking of something like this Drill Guide Attachment and using a hole saw without the pilot bit but forgot to attach a link.

I'd also invest in a diamond hole saw bit for this job. Fiberglass can dull a standard hole saw pretty quickly, especially if you have a solid deck.

08-16-2014 02:03 PM
Re: The WTF challenge!

Originally Posted by Minnewaska View Post
EZ outs were mentioned above, but there is nothing more difficult to deal with than an ez out, which had been broken off inside the stud.
Yea it does add another level of complexity when that happens.
I have to admit, any time that has happened to me it was self inflected due to lack of patience & too big a wrench.
08-16-2014 08:11 AM
Re: The WTF challenge!

While you're pondering the extraction, I would clean up the work site. Dig out or grind out all that old chaulk and vacuum. You're going to have to do it anyway. Clean the entire perimeter around the base of the studs flush to the deck and expose the sleeves. Get down to bare metal. It will help give the PB blaster or ATF and acetone mix a better shot at doling their thing.
08-16-2014 06:50 AM
Re: The WTF challenge!

EZ outs were mentioned above, but there is nothing more difficult to deal with than an ez out, which had been broken off inside the stud. Ask me how I know. Be careful with them.

I would make some heat and penetrating oil effort, but would quickly give it up for a drill. Cut the stud flush with the deck and either get a bit large enough to remove it (sleeve and all) or use as small a hole saw as you can. The hole saw is probably the way I would go, drilling stainless is very difficult. Then dremel a slot inside the wall of the hole, epoxy/glass it shut and redrill what you need. Use a good washer below that reaches original deck material, if you're worried about the epoxy.

As an afterthought, with all that corrosion, you're not considering reusing the sleeves? This looks like a do over.
08-16-2014 06:02 AM
Re: The WTF challenge!

With respect to the hole saw idea you can use a hole saw without the pilot bit and center the saw over your bolt. With care and practice you can do it freehand. Safer and easier is to cut a hole in a sacrificial board that is a couple of feet long. Center the hole over the bolt and kneel on the ends to hold it down as you ease the saw into the glass. Cutting through fiberglass generates a lot of heat so take your time. A helper with a vacuum cleaner to suck up the debris as you cut will improve visibility and make less of a mess below.

You already have holes for the existing bolts. Drilling them out and repairing them, drilling new holes, and throughbolting will not have any significant impact on structural strength.

A portable drill press, the sort you clamp a drill motor into, will help tremendously getting the holes square.
08-15-2014 10:09 PM
Re: The WTF challenge!

why is drilling holes hugely expensive? I just dont get why yards these days have ludicrous prices for the simplest things

basically yo are ripping something out, pluging back up and fairing then you are ready for your new installation
08-15-2014 10:06 PM
Re: The WTF challenge!

Man this thread is awesome! I should have hauled out at the SailNet yard! I'm learning lots of tricks.

JimMcGee- One of the things I liked about the nauticats is that the decks are solid fiberglass. No wood. No core. No need for exotic drill-fill-drill-seal procedures. I figured I can move my deck hardware and running rigging about with reckless abandon and not worry about ever having leaks which some day create the dreaded spongy deck.

The yard did originally suggest drilling out around the bolts with hole saws but they were suggesting a pretty big hole and back-fill. It was a HUGELY expensive quote and I was worried about the structural weakening of such big holes with just filler instead of contiguous glass. I care, because the deck is structural. So much so that my deck stepped mizzen doesn't even have a compression post or bulkhead below it. Just deck.

Smaller hole saws with large washers might be a good way to go...

Delta-T- I think I REALLY like what you've done with that project. Thanks for the links to the exotic fasteners as well.

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