7850001030 Automotive Service Technician Specialty Hand Tools FIRST PERIOD Safety, Materials and Tools© 2018, Northern Alberta Institute of Technology (NAIT) and Southern Alberta Institute of Technology (SAIT). All Rights Reserved. No part of this publication may be reproduced, stored in or introduced into a retieval system, transmitted or communicated in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the prior written permission of the publishers, NAIT and SAIT, except as permitted by law. For permission requests, please contact: NAIT and NAIT's logos are registered trademarks of NAIT and may not be used without the prior writen permission of NAIT. SAIT and SAIT's logos are registered trademarks of SAIT and may not be used without the prior written permission of SAIT. Other logos, trademarks, registered trademarks and tradenames depicted herein are the property of their respective owners, Use of them does not imply any affliation with or endorsement by them. All reasonable efforts have been made to ensure that this publication is accurate, reliable and free from error at the time of publication; however, there may be instances where information contained herein is not current. To the fullest extent permissible under applicable law, NAIT and SAIT disclaim any and all warranties and conditions respecting this publication, whether expressed, implied, statutory, or otherwise.Table of Contents Objective One... Tubing Objective Two... ‘Twist Drills, Drill Problems. Taps. Objective Three. Thread Repair Techniques Broken Stud and Bolt Removal Self-Test nnn Self-Test Answers, Glossary.Specialty Hand Tools Rationale Why is it important for you to learn this skill? ‘You will often encounter situations where it is necessary to replace a fitting on tubing, drill out damaged or broken fasteners and rethread components. Being skilled and knowledgeable in these procedures allows you to be more productive and efficient when repairing a variety of automotive systems, Outcome When you have completed this module, you will be able to: Use specialty hand tools common to the trade. Objectives 1. Perform double lap and SI tube flaring. 2. Use drills, taps and dies. 3. Demonstrate thread repair and broken fastener removal. Introduction Daily, automotive service technicians are exposed to many different kinds of threaded fasteners and tubes. This module will give you the knowledge necessary to produce double and ISO tube flares. The use of drills will also be discussed. You will learn how to repair damaged threads and accurately create new thread threads using taps and dies. TI module will also teach you how to remove broken threaded fasteners. Becoming proficient with these tools and techniques is an important part of being an automotive service technician. WOTOTIPET A apartObjective One When you have completed this objective, you will be able to: Perform double lap and SI tube flaring, Tubing ‘You will find tubing used in places such as the brake system, fuel system, automatic transmission cooler lines, power steering and vacuum supply system. Some tubing need only withstand low working pressure, such as automatic transmission cooler ines and vacuum lines, while others, such as brake and power steering lines must withstand much higher working pressure. Tubing Material Most tubing found on vehicles is double-wrapped, brazed steel tubing. The tubing is ‘manufactured by rolling copper-plated sheet steel until it has two layers and one seam, as shown in Figure 1. A furnace brazing process fuses the seam, creating a strong seamless double wall tube that is then tin-plated for corrosion protection. All rigid brake lines must bbe steel tubing. Figure 1 - Construction of double-wrapped steel tubing. Copper tubing becomes work hardened from bending and vibration, which can lead to brittleness and breakage. Never replace steel lines with copper tubing. Tubing Size ‘Tubing is measured by its outside diameter (OD). Common imperial sizes are “/i«", '/a", S/jg", 5/5" and "2". Common metric sizes are 4.75 mm, 5 mm, 6 mm, 8 mm and 10 mm, WOLOTHPITO_apaatadTubing Flare Types Flare connections ofien join tubing to components. A flare nut seals the flared end of the tube into the fitting. Generally, two types of flare fittings or flare muts are used on the modern automobile: the SAE double flare and the International Standards Organization (ISO) bubble flare (Figure 2). SAE tubing flares may be either imperial or metric sizes, but the ISO flare is always metric. Since both types of flare fittings are commonly used, take particular care to ensure you properly identify which type of connection you are working on. Interchanging, ISO and SAE flares causes leakage and creates a safety hazard. rv gail i Iso \ i SAE o / SAE Flare Seat 180 Flare Seat Figure 2 - SAE and ISO (SI) tubing flares. Flaring Equipment To properly form a tubing flare, you require a tubing cutter, tubing reamer and a tubing flaring tool kit. A typically flaring kit contains a gripping or flaring bar, rod handle, yoke and adapters. You also need a tubing bender to correctly form the tubing to fit the application (Figure 3). Tubing Bender Yoke % s Tubing Cutter Gripping Bar Lelie) (faring bar) Figure 3 - Flaring tools. OLOTEPTT apesCutting the Tubing Automotive tubing is sold either in ready-made, pre-flared lengths with two flare nuts, installed, or in bulk 25 ft rolls. To unroll the bulk tubing, hold the end of the roll on the surface of a clean workbench and carefully roll out the required length of tubing along the surface of the workbench (Figure 4). R ay Hold Here Figure 4 - Unrolling tubing from a 25 ft roll Cut the tubing squarely, using a tubing cutter. Place the tubing against the rollers with your cut mark positioned under the cutting wheel (Figure SA), then lightly snug the cutter Against the tubing using the handle (Figure 5B). Roll the cutter completely around the tubing until the rolling resistance disappears. Advance the cutter in small increments and roll it around the tubing afier each advance until the tubing separates. \ NCUA Figure 5 - Tubing cutter. WBOTOTHPET O_apaatedDeburring the Tubing ‘The cutting wheel distorts the tubing inward slightly, which leaves a lip or burr on the inside diameter of the end. Deburr the tubing with the reamer blade of the tubing cutter (Figure 6). Ream only enough to remove the burring. Excessive reaming results in incorrectly formed flares. Hold tubin down. Correct Deburr —+ Chips fall Tes Cut Square —| \ Flat Reamer Burred i Over Chamfered —-k Figure 6 - Deburring the tubing. Forming the Flare There are many different tools available to form SAE and ISO flares. Figure 7 illustrates several of the most common flaring tools. Carefully follow the instructions for each of the tools. Figure 7 - Flaring tools. DOTOTIPITO apdatNO 4 ES The flares do not form correctly if the tubing is not prepared properly. The end of the tubing must be cut squarely and be correctly deburred. A properly formed double flare is shown in Figure 8 as well as some common malformed examples. Not Cut Cone Not Squarely Overtightened Centred Insufficient Material Excessive Material Good (flare too small) (flare too large) Figure 8 - Finished double flares, ‘HOTOTTRET O_apaatedObjective Two When you have completed this objective, you will be able to: Use drills, taps and dies. Twist Drills A twist drill or drill bit (Figure 9) is a cutting tool used to bore holes or enlarge holes. It is clamped in a chuck driven by a portable drill or a drill press. Figure 9 - A twist drill or drill bit, Parts of a Twist Drill A twist drill is divided into three main parts, as shown in Figure 10. They are the: © shank, © body and point. }-— shank —+, Body ————___—+| Figure 10 - Parts of a twist drill, ‘Shank ‘A twist drill is held in a chuck by its shank. The drill bit size is stamped on the shank so it can be identified at a glance. The drill material is often stamped here as well, and will appear as HC for high carbon steel or HSS for high speed steel. Body ‘The body of a twist drill has two helical flutes (spiral grooves) cut into it. These grooves allow the chips to curl and come up and out of the hole as well as providing a passage for cutting fluid to reach the tip. Most drills have a right-hand helix, which means when you look at a side or end view of the drill, the helix falls off to the right. Left-handed drilis have a helix that falls off to the left and are used when drilling out broken bolts. ‘The margin is a narrow raised section that runs along the flutes for their entire length. The diameter of the drill is measured across the margins and it is the margins that determine the full diameter (size) of the drill. THOTOTIPET A apa‘The body of the drill is cut back behind the margins to provide clearance and reduce the friction created while the drill is turning in the hole (Figure 11). Margin Figure 11 - Drill body. Point ‘The point of the drill is where the cutting takes place. It resembles a cone with two equal length lips or cutting edges. The chisel edge is the portion remaining between the flutes at the tip. The heel is the area that is ground away behind the cutting edges providing a lip clearance (12°) which allows the drill to advance into the work piece (Figure 12). CChiset Edge Up or Cutting Edge Flute Figure 12 - Drill point, Drill Point Angle Drill point angle is measured from the cutting edges and the centre axis of the drill using a drill point gauge as shown in Figure 13. Figure 13 - Drill point gauge. ‘DoaTOTIRET updatedThe standard drill point angles are 59° measured from the axis of the drill, or 118° between the two lips, which is called the included angle (Figure 14). (. Figure 14 - General purpose point angle. ‘You can grind the drill bit to decrease the angle for softer materials such as plastic and, aluminum (Figure 1SA) or increase this angle for drilling harder materials such as tool steel (Figure 15B), A B 36° 90" Figure 15 - Decreased and increased drill point angles. Drill Sizes Drill sets are sized in four ways: fractions of an inch, numbers, letters and metric, Each sizing method has its own distinct formula to incrementally increase fiom the smallest drill in its range to the largest. ‘© Fractional sized drills are available in diameters from '/jsin to '/3 in or larger (1.6 mm to 12.7 mm). They inerease in size by increments of '/ in (0.4 mm). ‘© Number sized drills are identified by a number ranging from 80 (smallest) to 1 (largest). A number 80 is 0.0135 in (0.34 mm)and a number 1 drill is 0.229 in (5.8 mm) in diameter. A common number sized drill index contains 60 drill bits ‘numbering from 60 to 1, representing sizes from 0.040 in to 0.229 in (1.0 mm to 5.8 mm), Number sized drills have diameters that fall between the fractional sized drills and the increment between sizes increases as the drills get larger. © Letter sized drills range from A (smallest) to Z (largest). The letter A drill has a diameter of 0.234 in (5.9 mm) and Z is 0.413 in (10.5 mm) in diameter. The letter range picks up where the number range leaves off. In other words, the smallest letter (A) is larger than the largest number drill (number 1). Letter drills have diameters that fall between the fractional sized drills. © Metric sized drills are measured in millimetres. A typical metric drill index has 25 bits ranging from 1 mm (0.039 in)to 13 mm (0.512 in), increasing in increments of 0.5 mm (0,020 in) from the smallest to the largest. ‘OTOTHRETO_apaaiedras Drilling Hints Pay attention tothe following items to prevent problems that could affect the accuracy of the hole and the efficiency of the drilling operation. ‘© Choose the correct size drill for the hole size intended. * Set the correct speed for the size of the drill and the type of work piece material, «For small diameter holes, mark the work with a centre punch first to prevent drill wander. For holes %/ in (10 mm) or larger, mark the work with a centre punch and then Grill a pilot hole with a drill that isa little larger than the dead centre or the chisel point of the drill size being used. © Use the proper cutting fluid for the material. «© Lfexcessive pressure must be applied during a drilling operation, the reason is ‘generally a dull drill or a chip caught in the hole between the drill and the work. Correct these conditions before proceeding, «Ifyou have used the correct speed and cutting fluid, the drill will be cutting smoothly, with an equal amount of chip or curl coming out of both flutes (Figure 17) Figure 17 - Equal amounts of chip or curl when conditions are correct, ‘DoOTOTTRET 0 wpaaiedCutting Fluid Friction causes the cutting edge to heat up as a drill cuts. This can soften the cutting edge, which dulls the drill. A cutting fluid is used to: * cool the drill and retain the cutting edge, cool the work piece, help wash away the chips, permit faster cutting speeds and improve the finish of the hole. ‘Some metals do not require you to use cutting fluid. Table 2 shows which materials ‘require cutting fluid and which may be drilled dry. Material Fluid Requirement Brass Dry Bronze Dry Cast iron Ory Copper Dry ‘Aluminum Cutting Fluid Mild & Medium Steels | Cutting Fluid Tool Steel Cutting Fluid ‘Steel Alloys Cutting Fluid Table 2 - Cutting fluid requirements. Drilling Safety Before starting any drilling operations, you must observe the following basic safety precautions. ‘+ Know how the drill or drill press operates and how to stop it quickly. ‘© Always wear eye protection. ‘+ Never attempt to hold the work piece by hand, Clamp the work in a bench vise if using a portable drill. Clamp the work in a drill vise and use a C-clamp to lock the drill vice down on the drill press table when using a drill press, + Never change drill press speeds or adjust the work with the machine running, ‘© Unplug the cord before inserting or removing a drill from the chuck. * Keep loose clothing and hair away from the drill, ‘© As the drill begins to break through the work, ease up on the drill pressure. a (BOTOT HET O_opaaredIdentifying Drill Size ‘You can use three methods to identify the size of a drill. The first method is simply to read the identifying marks on the shank. The second method is to use a drill gauge (Figure 16). The smallest hole the drill fits into on the drill gauge is the size ofthe drill. This is a very fast and accurate way of identifying @ drill that has had its identifying marks worn off. Figure 16 - Using a drill gauge to size a drill. ‘The third method is to measure the diameter of the drill across the margins using an outside micrometer or vernier caliper. Locate your measurement on a drill size chart for the fraction, number, leter or metric drill that matches your measurement. Drill Speed = ‘The correct power tool rpm is required to prevent premature drill wear, breakage or damage to the workpiece. The speed at which a drill should be driven is determined by the size of the drill and the type of material been drilled. ‘The larger the drill, the slower it needs to be driven because the tool speed at the ‘circumference increases rapidly with drill size, thereby increasing heat due to friction. Drilling harder materials also causes more frictional heat from increased tool pressure: therefore the harder the material, the slower you must drive the drill. Table 1 gives the rill press speed (rpm) for a selection of drill sizes when drilling cast iron. Size of Drill | High Speed Steel! Drill_| High Carbon Steel Drill Te 2000. 900) le 1000 600 3 700 360) le 500) 250 ‘Table 1 - Drill press speed as applied to cast iron, THOTOTIPET 0 apesDrill Problems Drills are subjected to many different kinds of abuse, and you must recognize the types of problems that can arise in order to correct them. Table 3 is useful in diagnosing drilling problems. Problem Cause Remedy, Discoloration | Cutting speed too high Reduce cuting speed Not enough cutting fd Use more cuting Mud Poor toallfe | Cutting speed to high Reduce cuting speed Feed too high Decrease feed Feed 10 iow Increase feed Chipped cutting edges Do not overheat cil Point angle uneven Use cil gauge when grinding ‘Too much clearance Grind less clearance Dei chater ‘Set up not rigid enough Use heavier set-up Pilot hole too large Use a smaler pothole ‘Squeals andjams | Worn margins Grind dil Excessive heat | Use cuting fd Inadequate chip removal Withdraw dil to clear chips more often Blue chips Excessive heat Use cuting id ‘Table 3 - Drill problem chart. Oversized Hole If the point angle is not centred on the drill axis, or the cutting lips have unequal lengths, or both, the result is an oversized hole (Figure 18). Oversize Hole ‘Short Long ean Chisel Edge Figure 18 - Uneven point angle or cutting lips. ‘BOTOT REI O_apdatedTaps Tapping is the process of cutting internal threads in a previously drilled hole. Taps are ground from hardened high speed steel. The end of the shank is square so that a tap ‘handle can be used to turn or drive the tap into a hole, “The part of the tap that does most of the cutting is the taper or chamfer. Grinding away a portion of the teeth at a shallow angle produces the taper. This angle is relieved behind the cutting edge to keep the outer surface of the tap from rubbing in the bore (Figure 19). ‘The land is the portion of thread that is left after cutting away the flutes. The flutes are the grooves between the lands, which produce the cutting edge on one side of the thread profile, The flutes also provide space for chip clearance and a passage for cutting fluid. Taps can have two, three or four flutes, with four being the most common Parts of a Tap Figure 19 illustrates the parts of a tap. I Overall Le Shank Length Thread Length Chamfer | chamfer| ‘Angle Internal Centre Length of Square ‘Shank Dia, External Centre 4 Point Dia Size of " QS" 4 t Ce ute Figure 19 - Parts of a tap. Imperial Taps ‘You can identify imperial taps by the markings on the shank. The major diameter (bolt size), number of threads per inch and the degree of coarseness are stamped on the shank. For example, on a tap marked '/2 X 13 UNC: "Jz indicates the major diameter of the tap in inches, ‘© 13 indicates the number of threads per inch and © UNC (unified national coarse) gives the degree of coarseness of the thread series. WoOTOTHTT LapsedMetric Taps Metric taps are identified using designations that start with the letter M, followed by the diameter of the thread and the pitch in millimetres. For example, on a tap marked M4 X 0.7: * Mindicates that itis a metric thread, © 4s the major diameter in millimetres and © 0.7 is the pitch of the thread in millimetres. Pipe Taps Identified by NPT (national pipe thread) stamped on the shank, pipe taps are tapered the entire thread length (Figure 20) NOTE Only pipe taps produce tapered threads. Pipe threads are designed to wedge into each other to create a seal. Oil and coolant sensors use this style of thread because of its sealing properties. Pipe taps appear to be larger than the size of thread they create due to the fact that NPT sizes are determined by the inside diameter of the pipe. Common automotive pipe tap sizes are '/ in, V/s in, '/e in ands in, For example, on a tap marked '/s NPT: © ‘eis the inside diameter of the pipe in inches and ‘+ NPT refers to national pipe thread, Figure 20 - Pipe tap. ‘OTOTpET apaTypes of Taps ‘Taps come in sets of three, such as the set in Figure 21 and include the following. Taper Tap ‘Tapered about six threads from the end, this tap is the first tap you use in the set of three because the taper leads and self-centres the tap in the hole. When tapping a blind hole, you start with this tap because the long taper permits gradual removal of the metal as the tap is turned into a pre-drilled hole. (Note that a taper tap does not make tapered threads. ina hole). If you are tapping a hole that goes through a work piece, use this tap alone to do the job, Plug Tap Tapered about three threads from the end, this tap is used next after the taper tap when tapping a blind hole. Bottoming Tap A bottoming tap has no taper, but is chamfered on the last thread. It is used when the last full thread has to be close to the bottom of a blind hole. It is the final tap used in the set of three, Taper Plug Bottoming Figure 21 - A set of taps. Tap Drill Size Before a tap is used, the hole must be drilled to the correct tap drill size. The tap drill size is the drill size that would leave the precise amount of material in the hole for a tap to cut a proper thread. If the drilled hole is too small, the tap will be forced to cut too much material, will bind in the hole and may break. If the hole is drilled too large, the threads cut by the tap will be too shallow and the bolt or stud may strip the threads when torqued. ‘BOTOTERET updated‘There are two methods you can use to find the proper tap drill size: by looking at a tap rill chart or by calculating with the tap drill size formula, Tap drill charts are found in the glossary section of this module. When a chart is not available, the tap drill size can be found by using the following formula: Tap Drill Size equals Bolt size minus Pitch Example Select the drill to tap for a; X 13 UNC cap screw. Bolt size = "in Pitch = "/s in Convert to decimal form, (0.423 in (tap drill size) ‘The nearest drill size to 0.423 in is 0.422 in C'/s). ‘Therefore, *”/: in is the tap drill size for a '/2 X 13 UNC tap. ‘The tap drill size for metric taps is calculated in the same manner as for imperial threads, using the formula, Example Find the tap drill size for a M10 X 1.5 screw. Bolt size = 10 mm Pitch = 1.5 mm Subtract the pitch from the bolt size. 10mm =LS mm 8.5 mm ‘Therefore, 8.5 mm is the tap drill size for a M10 x 1.5 tap. Pipe Tap Drill Size Pipe tap sizes are determined by the inside diameter of the pipe. To find the correct tap drill size for pipe taps, use a tap drill chart. Tap Handles ‘The shank of a tap has a square end to accommodate a tap wrench (Figure 22). A tap ‘wrench is used to turn the tap into the hole. a Figure 22- Tap wrench. TWOTOTIPET apdT-Handle Use a T-handle tap wrench, such as the one shown in Figure 23, where a standard tap wrench is awkward or cannot be used. For example, you might use the T-handle tap wrench when tapping out an exhaust manifold stud where very little clearance is available. Figure 23 - A T-handle tap wrench. Tapping Lubricants Proper lubrication during the tapping operation is essential. Use cutting fluid when tapping to help reduce tap breakage, increase tapping speeds and give you a more accurate thread. Tapping Procedure Following is the procedure for tapping a blind hole (Figure 24). Figure 24 - Tapping by hand. ‘DoOTOTIPET O_upaated1. Mount the work in a vise. 2. Counter sink the hole slightly larger than the major diameter of the thread before — tapping. 3. Select the correct tap (read the tap drill size chart or calculate tap drill size) and proper size tap wrench to fit the square on the end of the tap. 4, Fasten the tap in a tap wrench (tap handle). 5. Use cutting fluid 6. Avoid bottoming the tap in the blind hole to help prevent the tap from breaking, 7. Use a taper tap to start the thread in the hole. Try to keep the tap as square to the workpiece as possible while exerting downward pressure. Tum the tap clockwise into the work two or three turns. 8. Reverse the direction of the tap wrench a half tur after every quarter tum of cutting. This will break the chip and help to prevent the tap from breaking. 9. Remove the tap wrench and check the tap for squareness in two places at 90° to each other (Figure 25). 10. Apply pressure to the tap wrench to bring it back perpendicular to the workpiece if the tap is not square. 11. Clean the hole by removing the chips at regular intervals. Repeat the same procedure with the plug tap, and then again with the bottoming tap to complete the hole Figure 25 - Checking the tap for squareness. Care and Storage of Taps Properly care for and store taps by following these procedures. © Clean the tap after each use so that there are no chips left in the flutes. ‘© Store the taps independently in wooden drawers or in their original plastic containers to protect the cutting edge. ‘oOTOT FRET O_upaateDies Threading dies are used to cut external threads on round stock or to repair threads on damaged fasteners (Figure 26). Dies use the same system for identification as taps. Figure 26 - Solid dies. Cutting Threads With a Die Use the following procedure to cut external threads with a die. 1. To cut an external thread on a round piece of stock, place the work piece to be threaded in the vise. Be sure the end is chamfered so that the die will start easily. 2. Lubricate the end of the work with cutting fluid 3. Mount the correct size die in a die stock. 4. Place it squarely on top of the work piece with the tapered side of the die facing down, 5. Press down evenly on both handles and tum the die clockwise two to three turns (Figure 27). 6. Check if the die has started squarely on the work. If t is not square, remove the die from the work and restart it squarely. 7. After every one-quarter turn (clockwise), reverse the die approximately one-half ‘tum to break the chips, then turn it back to where you left off cutting and make another one-quarter turn, 8. During the threading process, apply cutting fh frequently. Figure 27 - Cutting a thread by hand with a die and diestock. ‘HOTOTTRET O_upaatedObjective Three When you have completed this objective, you will be able to: Demonstrate thread repair and broken fastener removal. Thread Repair Techniques ‘Threaded fasteners sometimes suffer damage in the form of nicks or burrs to either the extemal or intemal threads, preventing the thread from mating with the corresponding part. The part can usually be reconditioned with tools such as taps, dies, thread files, thread chasers and die nuts. When internal threads are damaged ot stripped you may: ‘© drill and tap them to a larger size, ‘© plug the hole, then drill and tap to the original size or ‘¢ install a thread-restoring insert Drill and Tap Drill out the damaged thread to the next larger tap drill size and re-tap the hole for the new larger sized bolt. This is not always possible because the larger diameter may interfere with the original configurations of the workpiece or its mating par. Metal Plug Insertion Drill out the damaged thread to a larger size of hole. The new hole size must be large enough to insert a metal plug and allow enough wall thickness between the major diameter of the new thread and work piece. Weld the metal plug into the hole. Drill and tap the original thread size in the metal plug. Thread-Restoring Inserts ‘There are several types of thread restoring inserts. Two types detailed here are Helicoil® inserts and Tap-Loc” inserts. Helicoil® Inserts Helicoils® are formed from diamond-shaped stainless steel, or phosphor bronze wire material (Figure 28). Use Helicoil® inserts to restore damaged or stripped threads and to provide stronger threads in soft or weak materials. For example, stainless steel Helicoils® inserted into aluminum castings make the thread stronger and more wear-resistant. These inserts are available in a wide range of common thread sizes, Figure 28 - Helicoil® thread-restoring insert. BOTOTERET O_apdatedFigure 29 shows the Helicoil® thread-reconditioning procedure. Drill the damaged hole to the size specified in the instructions that come with the Helicoil®, Next you must use the special Helicoil® tap to thread the hole to the size specified by the manufacturer of the Helicoil” insert. Install the Helicoil® insert using the special installation tool supplied by the manufacturer of the Helicoil®. The tool rotates the Helicoil” and drives the tang into the tapped hole. Notch for Tang Tang Removal Coil Thread Insert Figure 29 - Helicoil® thread-reconditioning procedure. ‘The Helicoil® should be installed to within one-half tum below the surface of the workpiece. The insertion tool is free to rotate in the opposite direction, and can be removed once the Helicoil” is at the correct depth. The driving tang on the Helicoil” may be broken off at the notch with a punch. Tap-Loc® Inserts Tap-Loc insert is shown in Figure 30. This is a solid bushing type of thread insert, and can be installed in any material that can be drilled and tapped. Tap-Loc® inserts have locking keys in grooves machined into the insert. Tap-Loc® inserts come in common thread sizes. h.. Figure 30 - The Tap-Loc® insert. Follow this procedure for installing Tap-Loc® inserts. 1. Drill and tap a hole equal to the thread size of the outside diameter of the insert. 2. Serew the insert into the workpiece. 3. Drive down the locking keys into the thread after installation ‘DHOTOTHET 0 updatedBroken Stud and Bolt Removal Bolts and studs that have seized or rusted in a threaded hole often shear off when you try to remove them. The removal procedure depends on a number of factors, such as how tight the stud is and how much of the stud is left sticking out of the work surface. Use penetrating oil liberally and let the broken bolt, or stud soak for a few minutes. Snapped-off bolts and studs that are not too tight and that protrude from the work surface can often be removed by using vise-grip pliers to grip the stud, and tum it out, Left Handed Drill Bits If the broken bolt or stud is not too tight, use a left hand drill bit to drill out the centre of the bolt. This may remove the bolt from the hole. Stud Extractors Ifa bolt or stud twists off at the surface of the work, a stud extractor may be useful (Figure 31). Ki Figure 31 - Stud extractors. Follow this procedure when using a stud extractor. File the top surface of the stud flat and then centre-punch the centre of the stud. Select a suitable size stud extractor. Drill a pilot hole into the stud with a small diameter drill bit. Select the drill bit size stamped on the extractor (usually just smaller in diameter than the tap drill size for the threaded hole). 5, Tap the stud extractor with a hammer to obtain a good grip in the hole. Turn the extractor counter-clockwise with a tap wrench to remove the stud, BeRe BOT OTIPET O_apdattUpsetting You can use heat to upset a seized or rusted stud. Apply heat to the stud with an oxyacetylene flame. This results in the stud expanding in the relatively heavy, cold surrounding material. The large body of colder metal restricts the stud expansion and the stud upsets, meaning the stud grows longer, but retains its original diameter. When it cools, the stud contracts in direct relationship to its upset dimensions. In other words, the stud is smaller in diameter, but has grown longer. A light tap with a hammer or punch. may be enough to loosen the stud so you can remove it. Filing Flats In some cases, a stud shears off well above the surface of the workpiece. In this case, file parallel flats on the stud to fit a wrench (Figure 32). For smaller diameter studs use a hacksaw to cut a screwdriver slot in the stud. To help stud removal, apply heat or apply penetrating fluid and allow the fluid time to penetrate before removal. Notch File Two Flats | | Figure 32 - Broken stud removal by filing flats. Centre Punch and Hammer ‘You can also use a centre punch and hammer to remove broken studs. Tilt the centre punch and tap lightly near the outer diameter of the broken stud. The object is to turn the broken piece out by applying force at a tangent, so you will have to walk the punch around with broken stud as it turns. Take care not to punch into the area between the outside diameter of the stud and the workpiece. Punching in this area will permanently lock the stud in the hole, You can also use this method to remove broken taps. When using this method for taps, make sure to punch in the flute toward the outer edge of the tap. BOT OTHE O_apdatdPlug Welding In this method you weld a nut where the broken stud protrudes above or below the level of the workpiece surface (Figure 33), Place an insulating washer over the stud hole, then ‘set a nut that is about the same size as the stud on top of the washer and line it up with the stud hole. Weld the stud to the nut and fill the nut full of weld metal. Allow the weld to ‘cool, and then use a wrench on the nut to remove the stud. Weld Metal (metallic arc) Cardboard or Asbestos Washer Figure 33 - Plug welding for stud removal. (On studs broken off below the surface of the workpiece, be sure that the weld metal does not contact the workpiece. WBOTOTIpET Oops NOTESSelf-Test 1. Tubing used in hydraulic brake lines must be made from: a) ISO material, b) HSS (high speed stee!). ©) double flared steel. 4) double-wrapped, brazed steel 2. Two styles of tubing flares used by most vehicle manufacturers are: a) single and double lap. 'b) double and SI (ISO). ©) seamless brazed and double walled. 4) ISO and HSS. 3, Tubing should be cut with a: a) tubing cutter. b) hacksaw. ©) flaring tool 4) any of the above. 4, The drill point angle for a twist drill should be: a) 59°, b) 12°, ©) 136°, )_any of the above. 5. The lip clearance angle for a twist drill should be: a) 59°, by 12°. ©) 136°, 4) any of the above. 6. Twist drill sets may be sized using: a) fractions. ) letters and numbers. ©) metric. 4) all of the above. 7. Three taps commonly found in a sets of imperial taps: a) metric, imperial and pipe. b) ISO, HSS and HBO. ©) taper, plug and bottoming. d) UNC, UNF and NPT. 8. A tap marked ‘/5 X 24 UNF will create threads wi a) 24 threads per inch. b) “pitch. ©) @ maximum diameter of Sie in. 4) all of the above. THoLOTpITO opaated10. i. 12. Technician A says that when using a tap, it should be backed up '/» tum after each '/s tum of cutting. Technician B says that using a tap handle is not necessary and that the square drive on the end of a tap may be driven with a crescent wrench, Who is correct? a) Technician A b) Technician B ©). both Technician A and Technician B 4) neither Technician A nor Technician B ‘The correct tap drill for a */ X 16 UNF cap screw is: a) "hp in. » Q c) 17.5 mm. Cees The correct tap drill for a M3 X .5 bolt is: a) 0.164 b) R c) 2.5mm. @) ein, To remove a broken stud you could use a: a) serew extractor. b) tap drill. ©) Helicoil. 4d) Tap-Loc® insert Damaged internal threads may be repaired using: a) Helicoil®. b) Tap-Loc® insert ©) neither a or b. 4) either aorb. ‘oOTOTERET 0 updatedSelf-Test Answers 4d » a) a) b) ® °) 4) a) a) ©) 12, 13. a) @d double-wrapped, brazed steel. double and SI (ISO). tubing cutter. 59° 1, all of the above. taper, plug and bottoming. all of the above. Technician A Mhgin 2.5 mm, screw extractor. either a orb. THOTOTEPIT O apaatedGlossary Eee eee Tap Size | TP! | Series Series | Drill Size Tax 20 ~| UNC 7 Ox 80] UNF | fe Mex 28 UNF 3 1x e4 | unc | 53 Shex 48 | UNC Fo | | 1x 72 | une | 83 Shex | 24 UNF ip eel eee se | uNc | 50 ex | 16 | unc | ‘he 2x 64 | UNF | 50 x 24 UNF | Q 3x 48 | UNC | She "hex 14 | UNC | u 3x se | UNF | 46 Thex | 20 UNF |W 4x 4o | unc | 43 tex 13 | UNC | Me 4x 43 | unr | 42 | thx 20 UNF | % 4x 36 | uns | 44 | Shex | 12 | UNC | "be 5x 40 | UNC | 39 hex | 18 UNF | ke 5x 44 | UNF | 37 Saxe foe unc | Ym | | 6x 32. °|vUNG. |= 36. Sh x 18 UNF | | 6x 40 UNF | 33 %x 10 UNC 2h | 8x 32 unc | 29 Sex 16 UNE | ‘he ax 3e | unc | 25 | "ex 9 UNC |b tox | 32 | UNF | 24 Tx 14 UNF | %e 2x | 2 | unc | 17 1x 8 unc | '% 12x | 28 | UNF | 15 1x 14 | UNF |e thx 7 UNC | be tex | 12 | UNF | te ex 6 unc | "he tex | 12 | UNF | 1% - | UNC - Unified national coarse UNF - Unified national fine UNS - Unified national special Table 4 - Bolts, cap screws and machine screws. ‘OTOTERET 0 apa 2930 EE eee Tap Size | TPI | Series | Drill Drill Size | HSS Drill | HC Drill Size Thx 27 NPT R | te 2000 | 900 %ex 18 NPT | Ths | Mw 1000 600 ok x 18 NeT | he 4 700 350 ‘ex 14 NPT | 2 ‘b 500 250 Sex | 14 NPT hou Shs 500 200 1x | 11% | NPT | the vex | 11% | NPT | te tex | 11% | NPT | 1% 2x | 11% | NPT | 2h 2bx 8 NPT | 2% 3x 8 NPT | 3% Table 5 - Pipe threads and drill speeds. Table 6 - Tap drill sizes (metric). Distance Distance % Bolt Between | Diameter Bolt Between | Diameter Diameter of Drill | Diameter of Drill “inl Threads Gaal ea Threads cal (mm) (mm) [M2 04 16 25 195 M22 0.45 1.75 M24 3 21 M25 0.45 2.05 M30 35 26.5 | m3 05 25 M33 35 29.5 | M35 06 29 M36 4 32 M4 07 33 M39 4 35 M45 0.75 37 maa 45 375 M5 0.8 42 : : : M6 1 5 mas 45 40.5 Ma 1.25 68 | Maa 5 43 M10 15 85 M52 5 47 M12 1.75 10.2 M56 55 50.5 M14 2 12 M60 55 55 M16 2 14 Mea 6 58 M18 25 155 mea 6 62 M20 25 175 : - : ee eee ‘ooTOTIPET updatedThis learning material is the result of a collaborative effort between the Northern Alberta Institute of Technology, the Southern Alberta Institute of Technology, and the following Alberta apprenticeship training providers: Grande Prairie Regional College | Keyano College | Lakeland College Lethbridge College | Medicine Hat College | Northern Lakes College Olds College | Portage College | Red Deer CollegeQueen's Printer Stock Number: 7850001030 <—_-, agian <=, The Individual Learning Modules Initiative is committed to continuous updating and is interested in your comments regarding technical accuracy and clarity of presentation. Please visit our website to register your comments. To view the ongoing discussion, go to the Bulletin Board: http:/ilm.nait.ca The Individual Learning Modules Initiative would like to thank the many individuals and companies for their contribution and gratefully acknowledges their valuable input. Ordering in British Colum ‘Queen’ Printer Crown Publications, Queens Printer 1563 Superior Sveet PO Bor 9452 Stn Prov Govt Vicor, Bish Columbia Canada V8W 9V7 “Telephone: 280 387-6408 or 1 800 663-6105 Fax: 280 387-1120, Email: crownpub@ibe.ca web: wrwronenpub be ca Payment options by compa chee matey ade 0 pron {hue} nds paleo Minar of Fnno end Vin or Maser, ‘acannon. 090101f | Version 21 SAIT