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  • I need to drill out an M6 stainless steel bolt from an alu casing.

    Can someone recommend some easily purchasable drill bits to do the job.

    Also as a secondary question are things like JB Weld/similar strong enough to glue two nuts onto the thread of a bolt to create a new bolt head you can get a socket on?

    Cheers.

    (note to future self: Bolt, RHHF, M6 x 75 S/Less T3203075)

  • There are a couple of ways you could do it. In no particular order:
    1) Try a left-handed drill. I've never used one but they usually start drilling, grab a bit and wind the remains of the stud or bolt out. They're supposed to be pretty effective.
    2) Drill down the middle and use an Easy Out. I've had mixed success with these with both cheap and branded ones. I'd recommend branded ones with the shallow flutes like Dormer. The key to these is a) drilling the right size hole and b) knowing when you're giving it too much welly and making a judgement if it's going to break. There are some tips to making these work successfully.
    3) Drill it all the way out and helicoil. Easy peasy and always works.
    4) Weld a nut on the bit sticking out - works really well but only if you have a welder.
    5) Actually, if there's some sticking out you might get away with a stud extractor. Search for Irwin stud extractors.

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