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Drilling Fasteners for Lock Wire

  1. #1
    Member DanRo's Avatar
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    Drilling Fasteners for Lock Wire

    I tried (unsuccessfully) to do some drilling for the caliper bolts + axels for an 02 S650s.
    I will take all the screws off the bike and bring it to anyone who has access to a drill press vise to make the safety wireholes ..

    Let me know if anyone can help me out with this one or can recommend a place where I can use a drill press vise ...

    Thank you,
    Dan

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  2. #2
    Rookie Rada's Avatar
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    Re: Drilling Fasteners for Lock Wire

    Where are you located?

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  3. #3
    Member DanRo's Avatar
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    Re: Drilling Fasteners for Lock Wire

    Boston, MA

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  4. #4
    Unsafe At Any Speeds Jim's Avatar
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    Re: Drilling Fasteners for Lock Wire


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  5. #5
    Posting Freak Gecko's Avatar
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    Re: Drilling Fasteners for Lock Wire

    Quote Originally Posted by Jim View Post
    Damn, no pre-drilled header nuts. I saved the worst for last.

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    John
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  6. #6
    Lifer GMAN226's Avatar
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    Re: Drilling Fasteners for Lock Wire

    25,000 1/8" drill bits, 2 boxes of band-aids and $1,000,000 for the swear jar...

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    Gerard

  7. #7
    WMC original sdog30's Avatar
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    Re: Drilling Fasteners for Lock Wire

    I actually notice it's easier to drill them on the bike. Your gong to break a bunch of bits either way. If you use a center punch before drilling, it helps so much.

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    14 Triumph Street Triple R, 18 TM 450SMX sumo, 15 Husky 250SXF tard, 14 KTM 250SXF and Cole's Grom
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  8. #8
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    Re: Drilling Fasteners for Lock Wire

    ... and keep the bit cool by dipping it in oil often. I use a 1/16" bit, have posted this before:

    McMaster-Carr # 3146A112

    http://www.mcmaster.com/#3146a112/=rc7e03

    I've been drilling nuts and bolts for a long time, and still break bits now and then. If drilling straight through, you have a better chance of getting it done without breaking a bit. I usually drill through adjacent flats, twice on each fastener. The most likely time for the bit to break is emerging on the other side [when drilling through adjacent flats, that is].

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    Last edited by whynot; 04-01-14 at 07:32 AM.
    And don't believe everything you think.

  9. #9
    WMC original sdog30's Avatar
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    Re: Drilling Fasteners for Lock Wire

    Quote Originally Posted by whynot View Post
    ... and keep the bit cool by dipping it in oil often. I use a 1/16" bit, have posted this before:

    McMaster-Carr # 3146A112

    http://www.mcmaster.com/#3146a112/=rc7e03

    I've been drilling nuts and bolts for a long time, and still break bits now and then. If drilling straight through, you have a better chance of getting it done without breaking a bit. I usually drill through adjacent flats, twice on each fastener. The most likely time for the bit to break is emerging on the other side.
    +1 to this.

    I spray the bit with wd40 and stop drilling right before it breaks through and then hit it from the other side.
    Oh, and just buy new header bolts. Million times easier than trying to drill hardened header bolts.

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    Last edited by sdog30; 03-31-14 at 07:28 PM.

    14 Triumph Street Triple R, 18 TM 450SMX sumo, 15 Husky 250SXF tard, 14 KTM 250SXF and Cole's Grom
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  10. #10
    #331 CBR929RE's Avatar
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    Re: Drilling Fasteners for Lock Wire

    I only break them when I get impatient and put too much force behind the drill and bend the bit just before it snaps. going through the other side never broke one on me. I think the last ones I used were dewalt. I think they were Ti.

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  11. #11
    Lifer union's Avatar
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    Re: Drilling Fasteners for Lock Wire

    Quote Originally Posted by Gecko View Post
    Damn, no pre-drilled header nuts. I saved the worst for last.
    This your first year?

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    James

  12. #12
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    Re: Drilling Fasteners for Lock Wire

    Quote Originally Posted by union View Post
    This your first year?


    Just 'cause I've done it many times, doesn't mean I like it any more than the first time. Actually, I've gotten pretty good at it ... have done all the other bolts with one bit. However, the older I get, the less time I have for these more tedious tasks. Plus, I recall the header nuts being a PIA. In fact, now that I think of it, I ended up having to take a trip to the ER to have shards of metal pulled out of my eyeball from drilling (metal bounced off my cheek and under safety glasses) ... so, yeah, if they had pre-drilled header nuts ... I'd pick them up.


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  13. #13

    Re: Drilling Fasteners for Lock Wire

    Quote Originally Posted by Gecko View Post
    Damn, no pre-drilled header nuts. I saved the worst for last.
    Can't believe they still require header bolts to be wired! Typical case of, "that's how we always did it".

    What possible safety issue would happen if a header bolt fell off?

    Pretty sure this is a 2-stroke carry over.

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  14. #14
    Unsafe At Any Speeds Jim's Avatar
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    Re: Drilling Fasteners for Lock Wire

    Quote Originally Posted by TTD View Post
    Can't believe they still require header bolts to be wired! Typical case of, "that's how we always did it".

    What possible safety issue would happen if a header bolt fell off?

    Pretty sure this is a 2-stroke carry over.
    because the million spring clips and required safety wire to those hooks might spontaneously fall off and the exhaust header will fly out at a rider

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  15. #15
    Lifer union's Avatar
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    Re: Drilling Fasteners for Lock Wire

    Quote Originally Posted by TTD View Post
    Can't believe they still require header bolts to be wired! Typical case of, "that's how we always did it".

    What possible safety issue would happen if a header bolt fell off?

    Pretty sure this is a 2-stroke carry over.
    Well you know Tony its just in case all 8 nuts happen to back all the way off and all 4 springs holding the header to the flange break, and then the bolt holding the muffler loosens up enough so the exhaust system can move forward and rotate down and fall off the bike without the rider noticing something is up. Just one of those things.

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    James

  16. #16

    Re: Drilling Fasteners for Lock Wire

    ... and even if every bolt fell off, aren't there other bolts preventing the header from moving?

    Oh yeah... and then bodywork to "catch" the headers?

    Someone "higher up" needs to really review this rule's need.

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    Tony
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  17. #17
    Unsafe At Any Speeds Jim's Avatar
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    Re: Drilling Fasteners for Lock Wire

    i'm going to contact Pro Bolt and ask why they dont offer them in race spec

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  18. #18
    Posting Freak Gecko's Avatar
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    Re: Drilling Fasteners for Lock Wire

    Okay, so this is what the 2013 LRRS Rule Book says:

    19.17
    Exhaust systems must be securely mounted. The outer
    header nuts must be lock wired. All mounts and brackets
    must be wired and where possible, there should be a
    second means of securing the pipes. The baffles must be
    secured by a lock wire. Four cylinder inline machines
    need only lock wire the two outer exhaust pipes.
    So maybe four nuts, instead of all eight.

    I don't find the exhaust mentioned in the 2014 CCS Rule Book (I also want to be prepped in case I do NJ this year).

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  19. #19
    Unsafe At Any Speeds Jim's Avatar
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    Re: Drilling Fasteners for Lock Wire

    john CCS (NJMP) only requires: oil drain, oil filler, and oil filter wired...that's all.
    no calipers, axles, brake pads, radiator cap, exhaust, etc.

    that LRRS rule book says the outter header tubes are to be safety wired. so just the header tubes for cylinders 1 & 4 only.

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  20. #20
    I've been here before. Mustang's Avatar
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    Re: Drilling Fasteners for Lock Wire

    Actually it says the outer header nuts, not the outer header tubes - so that's two nuts, if the studs are positioned horizontally. If they're vertical, Tech could argue "four" nuts.

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    Bill Cool --- NEMRR EX #8 --- 2023 NEMRR GTO Champion, 2020-21 LRRS LWSS Champion --- RSP Racing / TTD / MTAG-Pirelli / Woodcraft / Sportbike Track Gear / Seacoast Sport Cycle

  21. #21
    Unsafe At Any Speeds Jim's Avatar
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    Re: Drilling Fasteners for Lock Wire

    ya but what are you going to wire them to?

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  22. #22

    Re: Drilling Fasteners for Lock Wire

    Correct, just the two outer nuts... they can be wired to anything.

    I'd rather people pay more attention to the exhaust can! If this comes off, then people can really get hurt.

    People need to understand that the bracket that wraps around the can needs to be tight. Lots of time you can wiggle the can in the bracket so it's really not doing anything to keep the can on the bike... just holding it up.

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    Last edited by TTD; 04-01-14 at 08:55 AM.
    Tony
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  23. #23
    Soul Rider Paul_E_D's Avatar
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    Re: Drilling Fasteners for Lock Wire

    Of course, there's always that 1 time. I had to avoid Jeff Wood's motard header in T2. LOL

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    Paul_E_D


  24. #24

    Re: Drilling Fasteners for Lock Wire

    yeah, with 2 strokers and single pipe open header type bikes... I can see it. But an inline 4 cylinder inside of a fairing... not so much.

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    Tony
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  25. #25
    I've been here before. Mustang's Avatar
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    Re: Drilling Fasteners for Lock Wire

    Quote Originally Posted by Jim View Post
    ya but what are you going to wire them to?
    A neighboring part or bracket. One of the studs on which the nut is not mounted. Anything.

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    Bill Cool --- NEMRR EX #8 --- 2023 NEMRR GTO Champion, 2020-21 LRRS LWSS Champion --- RSP Racing / TTD / MTAG-Pirelli / Woodcraft / Sportbike Track Gear / Seacoast Sport Cycle

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