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September 8, 2020

Exhaust Manifold Broken Bolt Repair Made Easy: Machine-Grade Drill Bit Tooling

Exhaust Manifold Broken Bolt Repair Made Easy: Machine-Grade Drill Bit Tooling
It is easy to misunderstand the term “drill bit," which refers to a cutting tool with a spiral flute that is used to cut wood, steel, concrete, or just about any other material. A standard drill bit can be manufactured in many ways. The most common and economically efficient process to form the twist or flute is to be stamped or crimped. The point and cutting edges are then ground for the correct size and application.
Accuracy is sacrificed during the common process of making drill bits. On the other hand, machine-grade tools are made for precision applications, where accuracy and repeatability are most important. Machine grade tooling is turned, ground flat, and incorporates features that deliver the precision and accuracy required for the application.
Machine-grade tools are made from high-quality metals like cobalt or carbide. Micro-points are added so the tooling stays on track. Cutting edges are ground at the complex geometries demanded by the hardest of materials, including titanium, boron, extra-strength, and case-hardened steels, most of which are encountered in exhaust manifold bolt repairs.
PROPRIETARY BUSHINGS ENSURE PERFECT ALIGNMENT FOR DRILLING
When it comes to Exhaust Manifold Broken Bolt Repairs, how drill bushings are mounted to an alignment fixture can be the difference between success and a costly failure. Threaded mounting bushings are most common in machine shops because of their superior accuracy. By contrast, solder-on bushings are less precise, but due to their low cost, they are a popular choice for home workshops.
However, for high-precision drilling jobs like repairing a broken exhaust manifold bolt, it is important to use proprietary bushings. These bushings have patented features that provide a perfect fit in the alignment fixture, ensuring that the drilling is done correctly.
Screws or clamping devices used to secure bushings increase the risk of a lost screw inside the cylinder head, add to error rates because of the clearance needed for applying the alignment fixture, and result in further complexity. Finally, a threaded mounting bushing incorporates a proprietary and patented precision machined edge, which mates to an opposite edge in the tool. This overrides the threads to bring the assembly into perfect alignment with the cylinder head.
MACHINE-GRADE DRILL BIT TOOLING IS DIFFERENT
Threaded mounting bushings assure perfect alignment and perpendicularity of tooling. How the tooling system is used will determine repair times and the quality. Machine grade tooling, when mounted in an air or electric power hand tool, must be treated differently than common drill bits in order to deliver the accuracy of the system.
PROPER DRILLING TECHNIQUES
First, accurate rotational speeds for each size tool is critical. If the RPM is too low, cutting will not start. If too high, cutting will stop due to high heat. Next, the drill chuck should be turned manually when inserting a tool bit into the bushing, which ensures a solid fit.
Also, turning the drill on and off, quickly and repeatedly, referred to as “bumping or toggling” is critical, as it allows the micro point, discussed earlier, to “seat” itself and allow the following cutting edge to engage and load equally. Finally, excavating chips by keeping the tool rotating, but periodically extracting and reinserting the tool will improve cutting and extend tool life.
Using machine-grade tooling and following the above steps will ensure a productive and efficient exhaust manifold repair that will boost productivity and keep your customers’ cars safe from carbon monoxide poisoning and running at peak performance. It is also important to make sure that the drill is running at the correct speed. The speed should be adjusted according to the material being drilled, with the goal of maximizing the cutting performance and minimizing the risk of chipping. Additionally, the use of cutting fluids can help to reduce heat and increase the life of the tooling.
WITH THE RIGHT SETUP, A SUCCESSFUL EXHAUST MANIFOLD REPAIR IS WITHIN YOUR REACH!
BROKEN EXHAUST MANIFOLD BOLT REPAIR SOLUTIONS

1 KIT = 20 GAS & DIESEL ENGINES

PowerTech Set - Charlie ProKit Part #: PMXPWT220PRO
Exhaust Manifold Bolt Repair for Ford 4.6L, 5.4L V8, and 6.8L V10 Gas, 6.0L, 6.4L Diesel; Dodge 5.7L and 6.1L; GM 1999-2013: LS 4.8L, 5.3L, 6.0L, 6.2L, GM 2014-Current: 5.3L, 6.0L, and 6.2L SAVE UP TO $300 and get a boatload of more stuff.

FORD 3.5L ECOBOOST EXHAUST MANIFOLD BROKEN BOLT REPAIR KIT

EcoBoost ProKit Part #: PMXEII200PRO
Ford EcoBoost 3.5L Remove broken exhaust manifold studs / bolts. For Ford F-150 and Ford Transit. Made In USA. Twin turbochargers, broken titanium bolts, small engine bays, along with dimensional changes in the cast iron manifolds due to extreme heat create new problems for the servicing technician.
Elizabeth II facilitates the removal of broken exhaust manifold bolts on Ford EcoBoost 3.5L and 3.7L engines.

PREMIUM PLATINUM DRILL BIT TOOLING

Platinum Bits: PMXPLTV125, PMXPLT188, PMXPLT266, PMXPLT270, PMXPLT420
High-performance tooling bits engineered to cut through the hardest materials and drastically increase productivity. Excellent for drilling extremely hard materials including broken extractors and taps. Also great for exhaust manifold repair, water pumps and valve covers.

PREMIUM GOLD DRILL BIT TOOLING

Drilling through extremely hard material including Titanium, Boron, Ultra-Strength, and even Stainless Steel is easy with ProMaxx Tool's premium gold drill (tooling) bits. Exceeds Aerospace Specifications. These are the best drill bits for drilling out exhaust studs and more.
Filed in: Drill Bits Premium Tooling, Exhaust Manifold Repair Kits
Previous article 3 Signs It’s Time For An Exhaust Manifold Repair: Replace & Repair Broken Bolts
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