39 door lock. Drill out hardened screw

[ActionYobbo]

So I had to drill out the hardened screw that held the door lock in. I used a TN coated carbide ball nose endmill in my battery drill and took my time and mostly kept it centered. Then I tapped the hole to 1/4-28 and made an insert from a piece of 1/4” tube that I threaded 1/4-28 on the outside and also drilled and taped to 10-24 on the inside. (I was going to do 8-32 but the hole in the tube was too big for that so I went up a size. If I were to make it from solid stock and center drill it then I would try for 8-32). I then coated the 1/4-28 threads with loctite 609 and screwed it in. When it dried run a 10-24 tap onto it to clean out any loctite that got into the 10-24 hole and it’s ready for the lock and new screw.

Originally Posted by Terry,OH

The original screw was 10-32.

Good to know
I went with the 10-24 because that’s what I had and it worked with the tube I had. If I had 10-32 I could have used it.
With the tube being 1/4” There is not much left after the inside and outside are threaded. So for more strength cutting it 8-32 would leave more metal in the repair but it seems it’s not needed my repair is working the lock is in and the screw is tight. I just used an ordinary cap screw with an Allen head.

[oldbugger]

Sounds like a great repair!

[ActionYobbo]

Originally Posted by oldbugger

Sounds like a great repair!

I posted how I did it so it might help some one in the future.

[19Fordy]

Good job. That's a tedious repair that requires the patience of a toothache.
Well done.

[stingywrap]

Using a TN coated carbide ball nose endmill to carefully drill out the screw and then tapping the hole to 1/4-28 to create a new threaded insert demonstrates your skill and ingenuity. Additionally, fabricating an insert from a piece of 1/4" tube, threading it both internally and externally, and using Loctite 609 to secure it in place shows attention to detail and a thorough approach to the repair.

super mario bros

[kiwi nz]

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Originally Posted by stingywrap

Using a TN coated carbide ball nose endmill to carefully drill out the screw and then tapping the hole to 1/4-28 to create a new threaded insert demonstrates your skill and ingenuity. Additionally, fabricating an insert from a piece of 1/4" tube, threading it both internally and externally, and using Loctite 609 to secure it in place shows attention to detail and a thorough approach to the repair.

super mario bros

Stingywrap, I am sure glad that you have got your post count up.

[Terry,OH]

The original screw was 10-32.

[ActionYobbo]

Originally Posted by Terry,OH

The original screw was 10-32.

Thanks
I modified my original post