Pilot jet stuck, in an impressive (impossible) way

2 out of 4 jets popped out easily, one more needed some soaking and an ez-out type tool to remove stripped threads.

Moving along to number 4, figure I would use same method as the first stuck jet.. this one feels very 'solid' compared to the others. ez-out is just bouncing out of the jet.

Bust out the magnifying glass and it appears the tapered square end of a small file is wedged in and snapped flush with the mauled jet.

Very little room to get a drill bit past before drilling into the carb body

Is this trash, or am I missing a tricky way to dig this thing out?

 

WHICH jet? http://xjbikes.com/Forums/viewtopic/t=31061.html

 

So you went the E Z out route right away, eh? Can you grasp the tip with a small vise grip pliers? Unsure which jet you mean.

 

maybe you could use a big drill bit and drill it till the "head" of the pilot jet comes off.
that might be a ez-out your seeing in there

 

The fuel pilot jet is stuck. In the small tube next to the main jet / emulsion tube.

Got 3 (35's I belive) out, 4th is stuck....way down.
The way the piece of ezout is stuck, it just deflects the drill bit.
I'll try to get a picture

 

best pictures i could get....

http://smg.photobucket.com/albums/v24/c3RX9/xj550/

 

do the pictures help explain how stuck i am?

thinking a small 2-finger type tool with sharp points might be my only option right now

 

Or maybe a dremel with the static mount and a fine metal bit to get a hole started.......

 

Just be careful not to damage any other parts in the carb; you may end up needing a replacement carb body and you want to have as many parts to pick from as possible, between the original and a replacement.

Get it soaking in Kroil http://www.kanolabs.com/google/ while you fabricate a tool.

Do you have a Dremel?

 

I have kroil, and a dremel. I think I have found a nice twisted pair of needle nose pliers that might get the grind. I'm trying to get the steel out first, save the metal closest to the threads for the 'last resort' effort.

Kind of wishing I did end up buying the dremel 100pcs. assortment at sears a few weeks back...

I have been tearing apart my 2001 Explorer in the mean time also, timing chain guide/tensioner failure :-(

 

That's being between a Rock and a Hard Place, ... whew.

The easiest "Fix" ... is a Body Swap.

Then, ... I always preface what to do ... NEXT ... with this advice.

Don''t make your BAD Situation, ... Worse!

That Carb Body can be "Saved".

Here's what I'd do.

I'd take what you have on a Road Trip to the nearest Regional Technical High School and, ... "Ask the Faculty Member in charge of the Advanced Machine Shop Skills" ... for his personal evaluation.
• Offer to buy lunch or gofer a Box-O-Joe if he saves your butt.
• Make a "Donation" to the Shops "Expendable Items Fund"

Haul it straight to the Pros:

Bring a GOOD Jet so that the Machinist KNOWS what he's dealing with.
My guess it that they'll do straight to E-D-M Removal.
Electrical -- Disintegration -- Machining.

The process will disintegrate everything in the hole leaving the alloy as good as new.

Some Mechanics call it:: Tap Burning

http://www.metal-disintegrators.com/

 

That is quite an interesting concept. I don't think anything in my area would have that, but I can always call around on Monday.

I think this carb body is already in the 'Worse" category.

 

Does it make you feel any better to know that you aren't the first one with this exact problem?

http://www.xjbikes.com/Forums/viewtopic/t=34226.html

There are some other ideas in that thread as well.

Also, I've got some carbide drills that should be able to cut through the steel stuck in the center of the jet, but I'm not sure I would be able to keep it on center that deep in the hole. Willing to try if you run out of other options. I'm close to Philly.

 

I somehow missed that post in my search.. this is the first time I've had one stuck this badly. I've taken the carb to a friends house and bolted it to the table under the drill press.

Whatever is stuck in here, it is VERY hard, deflecting every drill bit we have tried. I was able to get a small brass bushing to ride on the outside of the drillbit to keep it centered, we are thinking this carb may have the jet JB welded in... we uncovered evidence of previous damaged threads in a JB weld like mess.

It was a good effort though...! now, off to the parts for sale section

Thank you guys for your opinions and advice.

PS, rice.. where exactly are you? I'm about 30 mins north of Philly these days

 

Yeah, the bushing idea to keep the bit centered is a good one and that's what I would have tried, but if whatever is broken off in there is truly hardened, you're not going to get through it with your typical drill bit. That's why I was thinking carbide. It's probably a square cross section screw extractor and is mighty hard.

As for JB weld, no problem. JB weld will let go with heat. Not a big deal.

So, I'm a little unclear with your last post... Did you get the jet out? Did you mess up the carb body and now are looking to buy a replacement? Not sure what was your outcome.

Where am I? I'm about 40 mins north of Philly these days. :lol: Near Lansdale. You've got to be close!

 

we found that the jet seemed to be jbwelded in... no threads, and a lot of jbweld where it looks like it was drilled next to the jet.

I have a lead on a carb body already. If you're in Lansdale, and I'm in Souderton, I must drive faster than you if I can make Philly to 5 miles farther in less time. lol. Anyway, howdy neighbor

 

Haha! So what you're saying is that if you would have heated that area of the carb body to break the JB weld joint, you could have gotten that jet out with a sharp rap on the workbench. :wink:

lol, yeah you drive faster than me. Howdy neighbor!