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Seized Screws - Impact driver fail

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StPeter:
Cheers, Tom.
Put off until the weekend - SWMBO's birthday today (the bike was her present!) best not to start after a couple of glasses of wine!
Helicoil kit arrived today - there is a plan C!

StPeter:
Insufficient stud to weld to - I was worried that the crankcase was going to start dripping on to the garage floor!
Some delicate angle grinding to get it nearly flush to the crankcase. Put the cover back on and run a 6.5mm drill through the hole in the cover. This gives you a centralised (ish) mark in the stud. Run a 4.5mm drill bit through as square as you can get it. Follow up with a 5mm. I may have been lucky but using my favourite home-made tool (the bit of broken power hacksaw blade sharpened to a chisel point - more about which later) I was able to pick out the first half  turnof the original thread - enough to get a tap aligned. Plenty of lube and taking it very gently, I managed to recut the thread. I quit at that point - while I was ahead!

Going back to The Most Useful Tool In The World . . .
Get yourself a 1" power hacksaw blade. If you know some local machine shops you can probably scab some broken ones; if not buy a new one. Grind off the teeth on a bench grinder. Snap to length (wrap it in a rag while doing this in case a bit pings off). Grind the end square and put a bevel on one side (chisel stylee). You can use this for:
Anything you'd use a thin cold chisel for
Removing bricks from walls
Removing old pointing
Channelling cables in aerated blocks
Removing old gaskets
Cutting rivets and screws
Scraping old paint
Shaving wood - especially after burning paint off

In short, it takes an enormous amount of abuse; you can welt it with a hammer without it bending and you can get a good edge which can be resharpened in seconds. I have several of them of various lengths. I'd not be without them!

Bryanj:
At least its out, now don't forget the antisieze on the new ones!!

SteveD CB500K0:
A picture of the "tool of all tools" would be cool as I'm having trouble visualising your (otherwise excellent!) description.

meerkat:

--- Quote from: SteveD CB500F on July 23, 2012, 07:58:33 AM ---A picture of the "tool of all tools" would be cool as I'm having trouble visualising your (otherwise excellent!) description.

--- End quote ---
Hi Steve,
It's a modified one of these pictured below.
I have one somewhere in my collection of 'handy gear' that I used at work as a short straight edge, a weld chipping tool, scribing lines and lots of other things.

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