Removing a snapped Roll pin in a blind hole - BMW 1200GS RWD

[tedmagnum]

This is an example of BMW R1200GS Rear wheel drive. The same as the one I have been given to fix at work.. However, the roll pin you can see is snapped off flush with the casing. It is a 2mm hardened roll pin inside another sleeve. The pin is harder than a HSS drill bit.

I have tried cobalts but they break too.

I have heated it but no joy.

I have tried to anneal the pin before drilling but no joy..


This pin needs to be removed to change the bearing that it holds in place. It is another case of BMW RETARDED engineering which is oh so common.

Our manuals say "Remove roll pin"... Wow, helpful.

I have not drill the other side and I can not drill sideways. I am not allowed.


ANY IDEAS ????????????????? £1200 to replace the case

Thanks in advance.

Ted

 

[Keith 66]

Build up the roll pin with Tig gently bit by bit until theres something to pull on? Another way i once got a blind pin out was with a machined nozzle made to fit a grease gun it pumped the pin out, For that i drilled the side, you cant do that but you might use the hole down the middle of the pin?

 

[Wendelspanswick]

Does the roll pin pass through a groove in the needle roller bearing?

 

[Wendelspanswick]

Car body stud welder and slide hammer?

 

[Shox Dr]

Can you not drill from the other side, drift it out and then weld the hole up.



(BMW another company like Apple, everyone that has one raves about it, choosing to forget the glaringly ****** faults they have, not to mention the costs involved)

 

[Shox Dr]

Car body stud welder and slide hammer?

Good Idea

 

[tedmagnum]

Yes... The pin fits into the bearing/case. You can't see it. The roll pin is very short too. I considered mutilating/cutting the bearing but I would likely break the pin from the other side in the process. And the risk of damage to the case is high. It's my last resort. Stuff like this is nightmare when it's not your own bike.

 

[Fazerruss]

If you have the equipment Screw a small self tapper or bolt into roll pin then may be tig it on. Make a small puller to fit the head of screw. warm up casing with oxy accet then draw out with puller.

PS. I also now hate BMWs (bloody over complicated)

 

[Fazerruss]

Another option is to take it to an engineering shop with a spark eroder

 

[tedmagnum]

Yup... Spark erosion is an option.. Trying to avoid outside engineers though as it's a warranty job and if they **** it, we're not covered for it....

I've tried to put a self tapper in it but the hole is sooooooo small, the screw would be 1mm and just snap. That picture makes the pin look bigger than it is. And that top part is snapped off.

Keep the ideas coming. I'll try them all lol

 

[Pete.]

Is it as we see in the picture or have you drilled it down flush? If it's still like that I would cut the head off a small bolt that fits with clearance into the hole, insert it into the end to the depth of the protrusion with the thread poking outwards, silver solder that in then pull on the threaded end with a small slide hammer.

 

[tedmagnum]

Car body stud welder and slide hammer?

hmmmmmm.... Will that work on a 2mm pin ? I'll look into that. Cheers.

 

[tedmagnum]

Is it as we see in the picture or have you drilled it down flush? If it's still like that I would cut the head off a small bolt that fits with clearance into the hole, insert it into the end to the depth of the protrusion with the thread poking outwards, silver solder that in then pull on the threaded end with a small slide hammer.

It's snapped off flush (not by me).... The hole is about 1/2 of a 1mm.. Crazy.....

 

[AndyStobbs]

Speak to Elite grinding services in Ellesmere port. They are on the telford road industrial estate. You must be close enough given your location. They have a spark eroder too I'm led to believe.
You could also try diamond burrs in a pencil grinder yourself, I've had success going through some snap rings with diamond burrs, they were pretty hard.

 

[mfletch]

As above use a dremel with diamond drill or engraver bit

 

[Pete.]

You could try finding a close-fitting pin for the centre hole, filling the pin with hot candle wax then punching down the middle to try to hydraulic it out.

EDIT, actually scrub that idea, it's holding the bearing which must have a groove and therefore an escape path for the wax.

 

[Lawnmowerboy]

Try a good quality carbide drill. They won't die doing high revs in a hole like that though will snap of abused.

 

[CompoSimmonite]

As a last resort what about using a 3mm core drill into the alloy and then a 3mm replacement pin ?

Paul H

 

[tedmagnum]

As a last resort what about using a 3mm core drill into the alloy and then a 3mm replacement pin ?

Paul H

If it was mine.. I would try that.. I can't do that with a warranty job.... The faderland would not approve.. Main dealer bull**** !!

 

[madkayaker]

dremal with carbide burr. recent did a job for a lad at work that felt a torx bit was a good way of getting a suck brake nipple out of a aluminium calliper. it cut the torx out then carefully drilled rest out and job done