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On 15 Jul 2001, at 19:17, Henrik Larsson wrote: > This bolt is a 10.9 and I'm not looking forward to drilling that one > out. Has anyone done this or has some advice? Yes, I've done this. The way to drill these out is to drill out the straight part and grind away whatever part of the shank that is left, up to where the threads start, being careful to only remove bolt and not knuckle. Then make a guide that looks like a bit of tubing that fits in the straight part and has an ID the same as the drill you need to use. Get a new drill, very sharp, high speed steel, and drill using very LOW speed, lots of pressure, and coolant, water is fine. You just don't want the cutting edge to spin against the face of the old bolt material because that will harden it. So, keep it cold, keep it cutting. Once you are thru, use a round file to remove any remaining material until you break thru and see the helical threads the full length of the threaded section. Finally, try to pick out the helical portion of the bolt that remains there. I find that if I run a tap in there it will jam and bread loose part of the old bolt. Keep doing this until you have it all out. This is a royal pain and lots of work. You'll need a good vice to work in, and a steady hand. Also lots of patience.... Good luck. - ******************************* Jim Adney, jadney@vwtype3.org Madison, Wisconsin, USA ******************************* ------------------------------------------------------------------- List info at http://www.vwtype3.org/list or mailto:help@vwtype3.org