I haven't actually done that Cliff, but it sounds eminently doable. If I can find the little handful of them that I've got here I must have a play - Not enough room/metal to weld a decent chunk of metal on and then use a shifter? That's got me out of trouble in the past. > Hi All, > I have a problem with a bolt on my car. > > It was a Torx type star headed 10mm bolt which is supposed to be tightened to a torque of 15 ft.lbs and is one of three holding the pulley onto the power steering pump,. > When I tried to undo it the torx tool simply ripped the stars off leaving a round head. Just to make it worse it is typically in a awkward place to get too and part of the design of these beasts is that they flare out towards the base so forming their own washer. So I am now left with a cone shaped disaster zone. > Using a Dremel type slitting disc I formed a slot in the remaining head and so far using screw driver blades that fit into a 1/4" drive socket have sheared off four blades. I even tried heating it up using a Micro blowlamp. > > From this it seems that it does not look as though it is ever going to shift and so have hatched another plan. > > I intend to use a Diamond Core drill, as used for drilling holes in very hard marble tiles etc. I have used these when installing bathrooms. > > What I hope to do is place the core drill over the pointed head of the bolt and grind my way down to the pully face hopefully turning the bolt head into a stud. Thus I hope at least to be able get the pulley off. > > I was hoping to put a thread on the resulting stud and then put a nut onto it but there will not be sufficient clearance to get a die down it. The pulley therefore is going to have just be held on by the remaining two bolts with the stud just taking some of the drive load. > > The Question is, has anybody any experiance with using Diamond Core Drills to cut steel? > > Regards > > Clif > MODEL ENGINEERING DISCUSSION LIST. > > To UNSUBSCRIBE from this list, send a blank email to, > modeleng-request@xxxxxxxxxxxxx with the word "unsubscribe" in the subject line. > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > MODEL ENGINEERING DISCUSSION LIST. To UNSUBSCRIBE from this list, send a blank email to, modeleng-request@xxxxxxxxxxxxx with the word "unsubscribe" in the subject line.