Horncast Removal

[TurboTrev]

I'm trying to remove a horncast that probably hasn't been off since the scooter was built back in 1969. Has anyone got any tips for releasing the seized screws without shearing them? Is it worth getting a blowtorch onto the screw and/or the bit of the horncast where the screw is? Any help appreciated. Thanks.

[CHRIS in MARGATE]

Do you go to church?

Pray!

[Stevepshipley]

Heat, plus gas, plus gas, heat, repeat for about a week then pray

[St George]

If that does not work grind the heads off, put the horncast on the bench, more lubrication and heat then using small pipe grips on the stubs they should come out. !!

[TurboTrev]

^^^Thanks all for your suggestions - so far I've got 2 out and sheared one!

Is there anyone on the forum who can remove sheared screws? Spark erosion rings a bell as being the best method?? Thanks.

[hullygully]

as long as they aint st/steel screws, just drill down the centre of the screw carefully increasing the size from 1mm up to 4mm

[bazza3004]

I had to drill them out on a resto a while back but the threads were shot on a couple so drilled them a little larger and inserted rivet nuts.

[johnnyXS]

how did you get on Trev ?
probably too late but a popular method of removing sheared bolts/screws is to weld a nut onto them then use a socket

[TurboTrev]

how did you get on Trev ?
probably too late but a popular method of removing sheared bolts/screws is to weld a nut onto them then use a socket

Still haven't got past taking out 2 and shearing 1. I must get out to the garage and try the others! Welding a nut on sounds like a good idea, once I've sheared the rest of them I'll take it to my welder (he does mig and tig) and see what he says!

[Paul Slack]

Grind flat the bust part of the screw flush with the alloy.
Centre punch it.
Drill out the old screw using a smaller drill bit.
Tap out the remaining crap in the threads.

That's how I do it if nothing else works.

[TurboTrev]

Grind flat the bust part of the screw flush with the alloy.
Centre punch it.
Drill out the old screw using a smaller drill bit.
Tap out the remaining crap in the threads.

That's how I do it if nothing else works.

Thanks Paul, I now have a few options I can try.