Pelican IMS bearing stud has separated inside shaft

[Mark_T]

Future reference on drilling bolts...

File the broken stud end flat. Center-punch the exact center of the stud. This is the most important step because if you are off-center by even a little bit then chances are you will get fuct when you drill. Start with a very small drill bit and work your way up to not larger than the tap drill size. Now run a tap through the hole. Smear some grease on the tap first so it holds the chips and doesn't drop them inside the case.

This method has worked for me flawlessly many times. I don't even bother with screw extrators as I have found that even the good ones don't work most of the time. Once I had one snap off in the hole. Now try and get the bolt out with a hardened extractor snapped off in there!

Good luck with the fix. Looking at your pic with that off-center hole I'm thinking that your only way out of this one is going to be an over-size hole and a heli-coil. I would respectfully and kindly suggest that you should farm that job out as you do seem to be in a little over your head here.

[black_box]

Yeah Mark, you're right. I should've filed it down first. I did punch it myself, and it seemed pretty centered, but I guess not. Helicoil is probably the best way to go now, although I am nervous about going all the way through with it. Having 9 out 16mm of the original hole should be safe and is a lot less scary than drilling completely through the case and possibly dropping metal chunks in.

I did try the screwdriver trick, BTW, no dice.

Real question to me: WTF happened to the original bolt? I checked the torque wrench against another one that has a indicator instead of a click (by pulling and redriving a random bolt in a metal door frame), and it was true to within 1 ft-lb at 8ft-lb's. So the bolt that pelican shipped me snapped with less than 8 ft-lb's??? That's crazy. I must be cursed on this job.

[2000boxster986]

Found these on the web... similar to helicoils. Might be just the ticket for your fix.
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[black_box]

Went ahead and helicoiled it for the original size threads, with what was left of the old bolt still stuck in there! I did some measurements, and it's not possible that the old bolt is protruding past the case, but to be safe I dropped a big dollop of JB Weld behind the helicoil to permanently fix the old bolt in place and anchor the helicoil (due to there not being any fixed stop behind it).

[2000boxster986]

Yay! Sounds like it's coming back together. Good deal!