Thanks Walt. I’ve used these from Comet Kart Sales as well.

The drill blocks are great but you can buy an awful lot of drill bits for $26….

I’ve done both methods more times than I can count, they both work fine but you’ll break just as many bits either way if you don’t drill straight and keep them lubricated.

I really like the way Walt trims the cotter pins and bends them back, that’s slick for things like brake calipers that don’t get moved around much. I’ve found that high quality stainless safety wire with the special pliers makes a quick and neat job as well but there again you’re spending money that could be used for tires ;)

This would make a great sticky too, I can’t count how many times I’ve seen folks get turned away from the track because things aren’t secured properly. Good work Gif!!!!

John

Why not just take a nut the same size as the bolt you want to drill and drill a hole through that. Now you have your drill jig. Put the nut in the wise, screw the bolt in to the where you want to drill the hole and go for it, it’s really that easy.

I made one of these and use 1/16″ cobalt drills in a small drill press.  You could hand drill in a vise also but since I have the drill press that’s what I use.

http://i1297.photobucket.com/albums/ag34/mikeincoppell/Drill%20Jig/20130522_205133_zps215b88ef.jpg

Not sure if I’m lucky or good but I’ve drilled a ton of bolts, both stainless and high tensile, and haven’t broken a drill yet.  I can drill a bolt in literally 30-45 seconds and unscrewing the bolt from the jig deburs the threads.

I have a drawing I can share if anyone is interested.

Center drill countersunk bits will also work.

No need to file the bolt.  With a steady hand and the bolt in the vise, use the Center drill to start your hole, then change to the bit you want to drill through with.

Center drill countersunk bits are available from harbor freight and elsewhere.

bb

When drilling use higher rpm as the drill bit gets smaller. This is a basic surface feet per minute concept used in all machining operations. Do an internet search for drilling speed chart.