Another small project of mine to make my day job doable, not a not a daring and highly talented machining job but just good old fashioned get the job done type of thing.
I was doing a headgasket on a VW 5 cylinder gas engine that someone unprofessional had done before. On the intake manifold which is plastic there are through holes to allow you to tighten the manifold bolts down. The mechanic before me drove one of the screws into the through hole and when it stopped he thought it must be tight. It actually got jambed into the hole and seized into place. I had to take a long piece of round stock used as a punch to knock it back out.
I was able to put all the bolts into place in the manifold and hang it on the car but the problem came when I needed to tighten the two bolts through the holes provided in the manifold. There was just enough room to get at the one with a 6mm long ball tool, but the other one had no access from the top or bottom when installed on the engine. I needed a long 6mm allen head that I did not have, nor did any of the other mechanics I know. A call to Snap on and they didn't have one either. The mechanic before me probably didn't even realize that he had not gotten all the manifold bolts tight.
So I am wondering how in the world I was going to accomplish may task when I remembered that I own a mill that is just standing in the back room waiting for use. I ran up to the local tool store and bought a cheap 1/4' extension set for $16.99 that had two long 1/4' extensions in it and one long 3/8' too.
I chucked the shorter (12' long) 1/4' extension into my er32 collet block holder and squared up the square end as close as I could eyeball with a triangle off the bed. I figured it was as at least as accurate as the square end of the tool anyway. I found center with my edge finder on the round shaft and with a little arithmetic I was able to shave the end down to my final 6mm dimension. i rotated the collet holder carefully and shaved all sides to match. I purposefully left the dimension a little proud in hopes that it would grip the allen bolts tightly and not fall off. An added bonus I discovered is the little ball that is spring loaded in the extension remained and also helped in holding the bolt on tool.
The tool worked perfectly with about 3 inches stickout of the manifold to spare, and I was able to get the manifold tight. i also have 2 more potential allen tools left over from my purchase to use in the future if needed. All told once I remembered I had a mill and started to cut a tool to work I spent 20 minutes maybe to do the actual job. I know I am slow, and if I had thought it through I could have done a much more professional job and at least cut the same depth on each flat, I do have a DRO after all, but I needed to get the main job done on the headgasket first. Next one will be better I promise.
Again I wonder how people who don't have access to a mill or lathe or other such tools can get by.