Reamer-file

[OccupantRJ]

You know that situation that you sometimes get into where two through holes wont line up well enough to slide a bolt through? I have a solution for you. Take various sizes of coarse rat-tail files and cut the tang off of them. If you will take note, they are tapered, and the spirals are in a right hand twist. Chuck the file into a drill, run in REVERSE, and use it to ream the holes to match, while the parts are in position. Just push through like drilling. I have been using this method for over 30 years, and it works quite well. A drill tends to grab and possibly snap in this situation, but the file glides through like butter.
Now before the naysayers come on board blasting this, we all know that this would be classified as a no-no. If you ever use this method, you won't care. Just wear some face and eye protection, and use some common sense.

 

[jwith68]

Well, sure, the reamer-file method would probably work, but what you really need is special bolts:





Actually, your method might work better. Thanks for the tip!

 

[rsanter]

or you could just use a tapered cone type carbide rotary file and use it the same way you mention with your drill

bob

 

[OccupantRJ]

Yes, but the file method will reach through a lot of things the rotary won't. I have used it to align a 3/8 shear pin hole through a 3 inch diameter hollow shaft assembly. Stripper bolts were used as shear pins on textile crimper rollers where I once worked.