rgnprof wrote:
Basically, you're talking about a homemade version of what KCFDCapt linked to a few posts back... ryan
Yep, that's right. If that template outfit can help you out, sure, let them help. I didn't spend a lot of time on their site, but it seems the individual "templates" are part of a larger kit that includes some kind of drill guides and other required components.
It was about then, that I thought you could take the "bushings" that were mentioned above, and epoxy them in place to give you some really good alignment. That was before I saw your pix and didn't think you could get enough contact for the epoxy to hold the bushing in place to drill through it. Then, Epiphany! Home-Made Guide.
I believe, that if you can get a 3/16 hole, right down the middle, through to the bottom, with a Left-Handed-Bit, then Heat It, Beat It and Spray It... Then try a 1/4 Left-Hander... My guess is the piece will come out before he hole is done. Otherwise... 5/16 and a 5/16-18-USS Tap. You might need a standard tap then a "bottoming tap" with less taper on the end so you clean out closer to the bottom of the blind hole the bolt came out of. Or, buy one, clean both holes far as you can, then grind the tip off the tap and make it "bottoming."
Amazon Search for "reverse drill bit" showed lots of bits and bit + extractor sets. I think store brands like Craftsman, Husky, Cobalt, NAPA, would all be OK for this. Just don't go where the greeting is "welcome to harbor freight." Not for this job.
