Slightly off topic this but I sense people on this site will know how to help me.

I am rebuilding a 1954 Austin Healey 100. In fact it is a lot like the last two kit cars I've built as I have a new chassis which has been made to the original dimensions and a load of panels that I am welding to it to create the inner bodywork of the car. In effect it'll be a new car, just like a kit. The biggest difference is that it is a lonely world; there is not a forum like this with hundreds of people all similar jobs, hence my problem.

The previous own of the car/kit had the chassis galvanised to prevent it rusting. However, they didn't fill the holes that shouldn't have been filled with zinc prior to the process. The pedals mount on to a bar which pivots, when the brake is pressed, in two tubes welded into the chassis. Now the metal on the inside of these tubes is steel so the contact is smoothed by grease which is pumped into the bar and out through some small holes and groves cut into the bar. Hope that makes sense. Anyway, the bar is 0.741 of an inch in diameter (or there abouts) so I figure the tubes need to be drilled / reamed to 3/4" to accept it. The question is how do I get a 'bit' that diameter to actually do it? I should say that the tubes are about 8cm long, I only have regular hand tools such as a drill with a 13mm chuck and that the job has to be done on the car as the tubes are already fixed in the chassis. Also, in true locost fashion I am not the bank of England so I could do with a low cost solution.

Thanks
Steve

LocostBuilders » Photos » Steve Lovelock » AH holes.JPG

If I understand correctly, get a machinist to bore them/ream them on a lathe for you. Or send em to me and I'll do it for ya!

Scott.

I had a simlar problem once, what i did was to buy a flap wheel then i extended the flap wheel shaft and carefully reamed the bores till the bar fits




ABRASIVE FLAP WHEEL 20x20mm 120 GRIT BOX OF 10 GARRYSON on eBay (end time 17-Nov-10 16:33:27 GMT)3

Buy or borrow a 3/4" or 19mm diameter reamer. A hand one with a square drive to fit onto a tap wrench is best, but a machine one with a morse taper will also do. Again turn it with a tap wrench attached to the tang on the end of the morse taper.

quote:

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Originally posted by s6otty
If I understand correctly, get a machinist to bore them/ream them on a lathe for you. Or send em to me and I'll do it for ya!

Scott.

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I've probably got a 3/4 inch reamer going spare in my huge box of reamers - if I do you can have it for a fiver + p&p.

Let me know if you are interested and I'll have a dig through the garage tonight.

Tom

Haha, hmm, it was early when I read it, I assumed the tubes were loose lol!

I probably have a reamer, if no-one else can find one.

Scott

Thanks for the replies. I'd very happily pay a £5 plus P&P for one if that is possible.

Steve

Yep, I've found a spare one. See your U2U for payment details.

Cheers,
Tom