Author Topic: Broken Drill Bit  (Read 1522 times)

Offline Wandering longhunter

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Broken Drill Bit
« on: June 14, 2025, 06:11:50 AM »
While drilling the hole for one of the barrel pins, the bit broke below the surface of the stock and is pinning the barrel in place. The bit is not through to the other side so I cant back it out.

I was sondering if anyone can share some useful information of ways to get this out without messing up the stock?

Thanks in advance

Offline Old and Grumpy

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Re: Broken Drill Bit
« Reply #1 on: June 14, 2025, 06:39:53 AM »
Drill from the other side and use a punch?  Would be tempted to use a undersized bit and punch then "clean it up" with the proper or larger size latter. Sort of like digging a tunnel from both ends and hope you meet dead on. Can always make all pins bigger so they match.

Online whetrock

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Re: Broken Drill Bit
« Reply #2 on: June 14, 2025, 06:51:59 AM »
Here's a post from an old thread (originally posted by David Pennington in 2013).
Some guys make a hollow bit like David is suggesting out of a piece of small/thin brass or bronze tubing. I think hobby shops sell that kind of stuff.

https://americanlongrifles.org/forum/index.php?topic=25921.0

  David R. Pennington
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Re: Broken drill bit inside wood - how to remove
« Reply #5 on: March 22, 2013, 05:34:03 AM »
One way when all else fails is to make a tiny hollow bit with the center drilled out the size of the broken bit. In essence it is a tiny tube with some notches filed in the end so it will cut. If the bit is broken below the surface, start the hole with a drill the same size inserted in the tube, then remove the bit and drill down around the broken bit with the hollow bit and when the wood around the broken bit is relieved it will come out. You then will have a hole a little oversized that you can plug and re drill.
« Last Edit: June 14, 2025, 08:00:24 AM by whetrock »

Online whetrock

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Re: Broken Drill Bit
« Reply #3 on: June 14, 2025, 07:52:33 AM »
I haven't tried this myself, but I wanted to suggest it anyway. You can decide if it sounds useful.

If only just a short piece of the bit is broken off, and you think it's stuck in the lug, and if it's one of the lugs above the rod channel, then you may be able to turn the stock upside down and drill down through the rod channel with a good quality 1/8" bit, to cut/drill the wood around the broken drill bit. When you have cut enough, then you should be able to pull the barrel out with the drill bit still stuck in the lug. But that will only work if it's just a small piece of broken drill bit.

A hole drilled through the rod channel should be easy to patch. You can fill the drilled-out wood with epoxy from the top side, with some masking tape in the rod channel to keep it from running through. When all that is set up, then make a cosmetic patch for the rod channel by fitting a small inlay of matching wood into the spot where you had cut/drilled into the rod channel.

My thought is that a small patch in the rod channel can be done with matching grain orientation, and that should be much easier to match and hide than a patch in the side of the forearm would be.
« Last Edit: June 14, 2025, 08:02:49 AM by whetrock »

Offline Steeltrap

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Re: Broken Drill Bit
« Reply #4 on: June 14, 2025, 01:56:54 PM »
I would agree with drilling from the other side. But I'd suggest using a setup (see pic) where you line up the existing hole (place it on the point of the bolt in the vice) and carefully drill down to the broken bit. Be careful as when your new drill bit approaches the broken one....it could "grab" the broken bit and cause the new bit to go "wonky" (Yes...a technical term) and break more stock wood.

I'd get the bit to just touch the broken one, then use a smaller diameter punch to push the broken bit out.

I hope this helps.


Offline Nordnecker

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Re: Broken Drill Bit
« Reply #5 on: June 14, 2025, 02:42:09 PM »
Ah, yes…..the old “sudden design change” phenomenon.
You might be able to cut and lift a piece of wood from the undamaged side and glue it back down after removing the broken bit. You will definitely have to fill the hole and change the location slightly or your pin might go awry as well.
Glueing in a small patch isn’t the end of the world and is much easier than making escutions.
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Offline bama

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Re: Broken Drill Bit
« Reply #6 on: June 14, 2025, 06:01:57 PM »
This is not a way to fix the problem but a way to avoid the problem in the first place. Always drill your pin hole in the stock first without the barrel in place. This will allow you a path to clear a broken drill bit if it does break when drilling the lug.

The small 1/16" bits break very easy and have a habit of snapping in two when they are just exiting the far side of the lug. If the break is over the ram rod channel, you can go through the ram rod channel with an opening to access the drill bit. This opening can be plugged afterwards and will never be noticed. If it's the forearm lug, that's more of a problem. If you are working from a blank and have not thinned the stock down yet, you may be able to lift the barrel enough to break the bit agin in the lug mortise, take the barrel out and then dig the broken bit out from the barrel channel.
Jim Parker

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Offline Jim Kibler

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Re: Broken Drill Bit
« Reply #7 on: June 14, 2025, 06:31:53 PM »
Great advice, Bama.  Spin the small bits fast as well.  When as the bit begins to break through the underlug, you can feel it.  Slow the feed pressure at this point to prevent grabbing and potential breakage.

Offline Scota4570

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Re: Broken Drill Bit
« Reply #8 on: June 14, 2025, 06:53:13 PM »
That is unfortunate, there is good advice here. 

I'll add something more.  Do not drill 1/16" holes free hand, use a drill press and vice, or a milling machine.  Go slow and peck you way down.  Any side load or binding on those tiny bits will snap them.  The same advice goes for taps.  Using either free hand invites disaster. 

Offline P.W.Berkuta

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Re: Broken Drill Bit
« Reply #9 on: June 14, 2025, 08:56:28 PM »
Too bad this happened to you -- small diameter drill bits can break easily. I would first try the "drill from the "opposite side" suggestion and tap out the broken drill bit. You would be VERY lucky to meet the broken drill bit head on but what do you have to lose. K&S sells small diameter brass tubing - look for it online or a hobby store and make a tube cutter as mentioned above. Other than that I think you will end up patching a ugly hole in your guns forstock. Good luck!
"The person who says it cannot be done should not interrupt the person who is doing it." - Chinese proverb

Online whetrock

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Re: Broken Drill Bit
« Reply #10 on: June 15, 2025, 01:42:20 AM »
In the "good ole days" of the 18th c. these pin holes were probably drilled with a bow drill, typically held horizontally. Here's a link to a photo of one on Jim Bode Tools.
https://www.jimbodetools.com/products/9-1-2-inch-early-bow-drill-97380
I own an antique one almost identical to this one. They were turned by a steel bow and a cord, and worked like the bow and drill fire making tools that many of you are familiar with. But they were usually held horizontally, with the work piece in the vise.

The bits in these tools turned slower than what you get out of an electric drill or a drill press, and they were also made differently. They were not "twist drills" with helical flutes. They were spade bit designs, which basically have a solid shaft and a flattened tip with cutting facets filed into the tip. Hardened, of course. Some had a slight twist in the tip that gave a slight increase in cutting angle. All of the antiques I've seen were designed to cut in only one direction. They cut on one stroke and just drag on the return stroke. So the workman also controlled the pressure in relation to whether he was pushing or pulling. I've made several spade bits like this over the years for various purposes. Since they have no flutes, they are not as vulnerable to breaking as are modern style bits with helical flutes. If making them yourself you can harden just the tip and leave the rest annealed.

Modern "twist drills" will work at slow speed, and they will even work if mounted in an antique bow drill. I'm not a machinist, but I've been told that they are more likely to break when turned too slowly, or too fast. Charts for machinists tell at what RPM they cut the best. As I understand it, they are designed for higher speeds than what can be generated by a hand-powered tool. This is especially the case with smaller diameter bits like we are talking about for drilling pin holes.

One hack that can help you avoid breaking bits (without having to make your own spade bits) is to cut off most of the fluted section of a long shanked bit, and then resharpen the tip. What I'm describing is a bit with a long shank, which is of course solid, with relatively little of the fluted section left at the front end. The bit maintains more rigidity that way, and if it does break, then usually it will just be the cutting edge that breaks away. A drill bit like that does load up quickly, so you have to pull it out frequently to clear chips.

Of course, if you want to modify a bit to this configuration, you need to be able to sharpen it. That's best learned on a larger bit, of 5/16" or larger size, so that you can see what you are doing. I sharpen mine on a cheap electric bench grinder, just holding them by hand and checking the grind with strong reading glasses or an optivisor. Sharpening them without a grinding jig and a good grinding apparatus isn't something you want to do if you need precise tolerances, but it seems to work for me for most applications. There's plenty online about sharpening drills, so I won't elaborate.

Update: repaired the link to Jim Bode tools
« Last Edit: June 15, 2025, 03:01:35 AM by whetrock »

Offline Dale Halterman

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Re: Broken Drill Bit
« Reply #11 on: June 15, 2025, 05:45:34 AM »
I start with the barrel firmly clamped in the stock. Drill the pin hole far enough to mark the location on the lug, then stop and remove the barrel. Finish drilling through the stock. Then drill the lug without putting the barrel back in the stock.

I use a slightly smaller bit to drill the stock to make sure the wood grips the pin tightly.

I also use a drill press. Sue me.

Dale H

Offline Scota4570

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Re: Broken Drill Bit
« Reply #12 on: June 15, 2025, 05:53:20 AM »
For a highly accomplished builder drilling free hand is easy.  The first 1000 times were the hardest. 

A new builder may not have a feel for the bit flexing or the chips packing the flutes.   I was commenting based on how a less experienced builder could stack the odds in his favor. 

Offline Ky-Flinter

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MOVED: Re: Broken Drill Bit
« Reply #13 on: June 15, 2025, 08:22:40 AM »
The subject of this thread is How to remove a broken drill bit.  Replies with suggestions for resolving the problem are most welcome, as are related posts on how to avoid breaking drill bits.  The use of power tools or hand tools may be mentioned in the context of those suggestions and that is fine.

The replies arguing whether power tools should or should not be used in building longrifles are off-topic and have been moved to the Moderator files.

Bill and Jim,
If you wish to continue your discussion, please do so via private message, email, phone, etc., but not here.

https://americanlongrifles.org/forum/index.php?topic=85075.0
Ron Winfield

Life is too short to hunt with an ugly gun. -Nate McKenzie

Online whetrock

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Re: Broken Drill Bit
« Reply #14 on: June 15, 2025, 08:37:09 PM »

Wandering Longhunter,
Have you made progress on solving the problem? Which lug was affected?

Here's another option to consider ...  If the bit is stuck in a lug that is showing in the rod groove/channel, it may be possible to use a graver and just cut a notch in the lug to release the stuck bit. Then you could pull the barrel out. With the barrel out, would be able to get at the bit from inside the barrel channel.

This would of course damage or ruin the lug. But a new lug is not a big deal. It's also possible to repair a lug by soldering in a patch.
 

Offline Jim Kibler

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Re: Broken Drill Bit
« Reply #15 on: June 16, 2025, 02:53:11 PM »
Here's another option...  Take a very small burr in a high speed rotary tool and cut along the lug from the ramrod channel side to slice the pin.  If done carefully, you'll not have much material to patch and it will be under the ramrod as well.

Jim

Online whetrock

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Re: Broken Drill Bit
« Reply #16 on: June 16, 2025, 05:44:17 PM »

Erick Krewson just posted info on a set of diamond coated burrs, on a different thread. I'd think these would cut through a broken HSS bit pretty easily, if you follow Jim K's last suggestion. They would also cut the lug itself if you decide to go that route.

I think this whole set was less than $10 at Harbor Freight or some other el-cheapo place.

I use the one on the far left for slotting the lugs after I drill the initial hole.



Offline smylee grouch

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Re: Broken Drill Bit
« Reply #17 on: June 16, 2025, 06:07:37 PM »
I was about to post when whetrock posted about cutting through the lug IF you are lucky enough to have it accessible via the RR grove. Sounds like a good idea.