SuzukiSavage.com - Powder Coating inside Threaded Holes in Clutch Cov

philthymike

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Powder Coating inside Threaded Holes in Clutch Cov
04/28/20 at 15:18:24

Just finishing up changing my clutch plates and cam chain adjuster and suddenly find the oil filter cover bolts getting extremely hard to turn. I'm putting on the clutch cover I had powder coated last spring.
So I back the bolts out and noticed that their threads are worn down up to the point they were tightened up to.
I poke a tiny screwdriver down each hole and find it doesn't go down far as it should. I do the same thing with the old cover and compare the difference and find 3/8" difference in depth. Back on the powdered cover I start scraping the screwdriver around inside and what's in their starts getting crumbly. I turn the cover over and bang it against a piece of wood. Powder comes out, same color as the coating.
The coating place masked off the entire oil filter area but not the bolt holes for the filter cover.

I'm pretty pissed off.

Can these threaded holes be chased out or do I have to drill and tap them for next bolt size up?
Or just keep using the corroded old cover and call it a day?

BTW: regarding the clutch, the big 32 mm nut was only hand tight. Was slipping caused by this?

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Gary_in_NJ

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Re: Powder Coating inside Threaded Holes in Clutch
Reply #1 - 04/28/20 at 15:38:41

If it’s un-hardened powder (or even hardened) I think you could get in there with a awe or pick of some type and scrape it, or maybe grind down a flat head screwdriver into the perfect tool and grind it loose with that. Then you can simply vacuum it out or hit it with compressed air, but most certainly wear a mask and eye protection.

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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Powder Coating inside Threaded Holes in Clutch Reply #2 - 04/28/20 at 15:57:26 It's out. The problem now is the threads inside. I used too much force trying to put the bolts in and the threads on the bolts and the holes are jacked up. It's why I asked about chasing and/or tapping.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18112 Camp Springs, Kentucky Gender:	Re: Powder Coating inside Threaded Holes in Clutch Reply #3 - 04/29/20 at 04:11:28 Yep....chase the threads - what other choice do you have? First use a proper sized drill to get powder out of the hole, then a tap to get the powder out of the threads. Don't use a lube - but do take the tap out repeatedly and blow the holes out.
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Armen Serious Thumper Offline Half-Witted Wrench-Jockey from Jersey Posts: 1452	Re: Powder Coating inside Threaded Holes in Clutch Reply #4 - 04/29/20 at 06:17:03 Start with a regular tap. finish with a bottoming tap. Blow out the crap when done.
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justin_o_guy2

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Re: Powder Coating inside Threaded Holes in Clutch
Reply #5 - 04/29/20 at 06:55:30

Ohh, Dave,, A drill? If a drill,, hold in fingers,,

Make sure that tap is in the original threads and not cutting new ones,,

Eye protection and some kinda parts cleaner or something with the Red Straw, WD40 would be okay for blasting clean,, but Dave says No Lube, which I dont understand,, Im sure he has a reason,,

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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Powder Coating inside Threaded Holes in Clutch Reply #6 - 04/29/20 at 07:35:05 Are these JIS type the correct ones? https://www.mcmaster.com/blind-hole-taps/jis-thread-taps/
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18112 Camp Springs, Kentucky Gender:	Re: Powder Coating inside Threaded Holes in Clutch Reply #7 - 04/29/20 at 07:44:11 justin_o_guy2 wrote on 04/29/20 at 06:55:30: Ohh, Dave,, A drill? If a drill,, hold in fingers,, Yea....but one that is the proper size. From the sounds of it the bottom of the hole is loaded up with cured powder, and a tap won't get that out.
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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Powder Coating inside Threaded Holes in Clutch Reply #8 - 04/29/20 at 07:54:15 My tiny Philips head jewelers screwdriver worked well for grinding away the buildup in the bottom of the holes. That and banging the cover with a block of wood or rubber mallet.
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justin_o_guy2

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Re: Powder Coating inside Threaded Holes in Clutch
Reply #9 - 04/29/20 at 07:57:11

Yeah,, thats a possible I guess, but wouldnt the stuff at the top of the hole have been cured too?
I guess the best idea is
Go Slow
Dont take metal out
Check hole depths, compare to length of bolt and consider the part thickness to clamp.
A drill bit that is the same size or thousandths smaller than the outside diameter of the bolt is okay.But spinning it in a drill risks the threads inside.
Sound about right?

If the bolts are messed up, new ones are cheaper than screwing up the case

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The people never give up their liberties but under some delusion.- Edmund Burke.

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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Powder Coating inside Threaded Holes in Clutch Reply #10 - 04/29/20 at 09:01:49 As usual the Clymer book says nothing about the size or thread pitch or any details at all on the cover bolts. Not even torque rating. Are they JIS M5?
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Powder Coating inside Threaded Holes in Clutch Reply #11 - 04/29/20 at 11:06:15 Harbor Freight has digital calipers that read metric and Our stuff.
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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Powder Coating inside Threaded Holes in Clutch Reply #12 - 04/29/20 at 12:17:24 I'm just going to put the nasty old cover back on. Already started scraping the gasket off.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28890 L.A. California Gender:	Re: Powder Coating inside Threaded Holes in Clutch Reply #13 - 04/29/20 at 13:58:54 I think they are M6x1.25
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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Powder Coating inside Threaded Holes in Clutch Reply #14 - 04/29/20 at 14:05:11 verslagen1 wrote on 04/29/20 at 13:58:54: I think they are M6x1.25 Thank you.
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