Zetec oil jet disaster
Turbo Mini Forums

I got the cooling jets fitted on the weekend more or less (they still need a little tweaking) However disaster struck whilst fitting the final oil cooling jet and I managed to snap the 2mm drill bit in the block halfway between the bottom of the jet mounting hole and the oil gallery :( I'll try and post some pictures showing what happened, in the mean time I’m going to have to workout how to remove the remains of a HSS drill.

Does anyone have any idea on how I can get it out?

As an aside feel free to insult me.

Oh you twat!!

only kidding

why does it always happen on the last hole!!!

Does the hole need to be drilled bigger? if so you might be able to drill down to the top of the broken drill and get some long nose pliers on it.

EDM it maybe? pics would be good.

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1/4mile in 13.2sec @ 111 terminal on 15psi

get it well soaked and try and work it out, some dentist tools would be good for this. often find them cheap at dodgy carboots etc.

Edm would get it out but to do that would need a large machine so probably costly!! I've had broken taps removed before at work but only in small items so they can be put in the EDM.

It "shouldnt" be too tight in there if you can get down the side of the twist and give it some anticlockwise twisting. Its just finding tools to fit.

it will come out though eventually. need some patience though!!

Try a pure carbide bit and drill it out ... will need to use a pilar drill though as they don't like to be bent!

Failing that there is a company in Quedgley that might be able to help you, EDCM. They never seem to say anything is a problem!!

Every day is a school day ...........

How fast and how expensive ...... the same question...

yes spark it out, i used to build these machines

its costly though like the lads say

try using a tap remover you may well get it out with that

Edited by BENROSS on 22nd Nov, 2006.

if it hasn't broken through into the oil gallery, leave it and reposition another drilling.

carl

WWW.FORCE-RACING.CO.UK PLEASE CLICK HERE

Did a similar thing when working on my bike engine. Got old of a small cobalt bit drilled into it with that and used a left handed tap and it pulled it out.

to be honest you have no chance of drilling it out

carls idea is a good one

you could mig over the offending hole encasing the drill in there for ever if its in solid

and drill another hole at the side

but... its best to come out TBH

Yeah its best to come out, think of the weight saving

Bad luck. I personally would really want to get it out rather than risk it getting free another time.

Thanks Tom and Mini13, your kind words are greatly apprechiated

I've decided that it's got to come out as sods law states that if I leave it there it will work it's way free whilst the engine is in use.

I'll try and get a photo up tomorrow and I might even bring the bring the block up to Malvern for people to have a good look?

Here's a piccy, it's not great but it was the best I could do with my camera.



I was chatting to a chap at work about it and he suggested that I put a dab of super glue on the end on a piece of wire and see if I could fish it out. Well I got to say I didn't have any faith in this idea, but I thought what the hell there's not much to loose and what do you know, it work first try:

good job you got it out as it didnt sound very tight!

Useful idea!



Crack on now then.

Good stuff, no washers underneath mains bolts by the way.....

Don't worry Tom, the washers will be going in the bin along with the bolts, the only reason that they are still on there is so that I don't loose the main cap.

Are they M8 allen bolts !

Metro turbo weekend driver,Mini turbo in the making again!

glad you got that out,

must say i'm suprised the superglue worked though, i'd expect it to just capilery up the side of the drill making it harder to get out.

Cool trick.

What way are you trying to fit the oil jets ?

Ones Ive seen, drill into the man jounral galleries, pointing at the underside of the crown ( Subaru engines )

Ovciously Cossies use a pump mounted oil rail. Basically a bit of small diam pipe, with outlets pointing at the underside of the crown.

What are the Zetec jets like ?

9.85 @ 145mph
202mph standing mile
speed didn't kill me, but taxation probably will

no longer a series, but still 1.3 turbo.

here you go stevie found this on turbo phils site( think its his site anyhows

http://www.turbo-mini.com/44648/23109.html

no longer a series, but still 1.3 turbo.