A little tip to fix a big screw-up

[Cobra Doc]

When you break a bolt or screw on component that coints fluids under pressure and need to fix it with a heicoil and the drill press oerator gets a little enthusiatic and drills through the end of the bolt hole, all is not lost. This does take a little precision and a drill press. Find an O-ring that will fit the new bolt snuggly on the shank, be sure it's appropriate for the fluid being retained. You also need a drill bit that is bigger than the O-ring. Using just the tip of the bit champher the hole so that 1. the O-ring sits in at half it's thickness (a standard 118 degree cut drill bit usually works just right) 2. the new champher is is the width of the O-ring plus about 25% of it's thickness. Go ahead and install the heli-coil with the top thread below the champher. Slide the bolt through the accessory being replaced with what ever washers are required, then slide the O-ring on the bolt and torque it down. I learned this from an Army Master Sargeant when we had a "special" bird that had to get out quick. Months later we were able to replace the component that had been drilled through. In this case it was a hydraulic system. Our fix showed no signs of leaks. Keep in mind that you will be compressing the O-ring against a threaded part of the bolt so if you have to turn the bolt backward, the O-ring is trashed.
(Now that the Statute of Limitations is up, I can buy a drill press!!! )