Restoring The Mac Timber Bear ~ Remove Broken Bolt Pt 3

The worst broken bolt to repair is the last one.
When the bolt broke off someone attempted to drill out the broken bolt. Instead of using a small pilot hole to remove the center of the bolt followed by a drill big enough to remove the root diameter of the bolt leaving only the threads, they decided to drill the hole out larger than the original bolt diameter.
They also didn’t guide the bit, either by hand or with a drill press. The bit wandered off the hard bolt and drilled into the magnesium next to the bolt. Ooops!
Here is where a simple split bushing lets me use the fan shroud as a drill guide. I can successfully drill the hole by hand by using stepped sizes. With the pilot drilled and the tapping drill run through the damaged thread is restored.
With the threads restored I can begin assembly. 😆😎

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