Greasable Bolts
Well I got a ton done this weekend and took several pictures, so I am going to start with the bolts I modified.
BOM:
(6) 9/16-4" UNC Grade 8 Bolts (I need (2) 5" and (4) 4")
Grade 8 flat washers, lock washers, and nuts
(6) 1/4-28 UNF Grease Fittings w/ 7/32" thread length
Tools:
3/32" Drill Bit (I used TiN coated bits, Cobalt would be better)
7/64" Drill Bit for when the 3/32 snapped
7/32" Drill Bit (#3 is the correct size for the tap, but 7/32 will suffice.)
1/4-28 UNF Taper or Plug Tap
1/4-28 UNF Bottoming Tap (I didn't have one of these, it will be beneficial though).
Tap Handle
Center Punch
Hammer
Drill Press
Drill Oil
Drill Vise
WD-40 or pressurized lube.
Grease Gun
Directions:
In a perfect world, you should be able to chuck the bolt and clamp the 3/32 in the drill vise and spin the bolt for get a center hole. I did not have this luxury, so I got it as close as I could with the center punch.
1. Center punch the bolt head in the vise or using the spinning technique above.
2. Clamp bolt in drill vise and slowly drill 3/32" hole 1.5" through the head using adequate drilling oil. I used a slow drill speed and frequently had to back the bit out to clear the debris from the bit and hole.
3. Put the bolt in the vise and center punch the shaft at just above 1.5" so you pass through the center hole drilled.
4. Lay the bolt in the drill vice and gently start a pilot hole through the shaft. You'll notice that once the bit makes contact with the shaft, it will try to slip off the rounded surface. Be very careful, or the bit will break here. Once the hole is started rotate the bolt so the hole is completely vertical, and drill through the bolt completely. Use drilling oil.
5. Place bolt upright in the vise again to drill the head with 7/32 or #3 bit. If you have a bottoming tap, set your drill depth on the press to 1/4", making sure that the zero on the scale has the bit touching the head. If you do not have a bottoming tap, set the drill depth to 3/8" because you will need the extra space to fully engage the threads on the tap. Drill the hole and use oil.
6. Place the drilled bolt in the vise and use the handle with taper or plug tap to start the threads. Once the tap bottoms out, if available, use the bottoming tap to complete the threads. Once again, use oil.
7. That's it, use WD-40 or some pressurized oil to remove the chips from the holes and then thread the grease fitting in and pump the bolt full of grease a few times to remove the chips.
Installed:
The shackle to spring eye bolt in my case needs to be longer.
More to follow