Question About How To Make Square Holes Out Of Round Holes

madmike · Post by **madmike** » Mon Jun 25, 2012 5:42 pm

On the inside of my A1 tub rear panel, there are two square holes that carriage bolts are used to secure the spare tire carrier. I had my rear panel replaced due to being dented pretty badly and the metal stretched beyond being able to make a nice panel. In hindsight, I would now hide the damage rather than have to try and fix the stuff that was done poorly manufacturing the panel but that's another story. Except for the bolt holes. That were not put in the new panel.

I will be drilling two holes for the carriage bolts but then need to make them square. It seems I saw something once on how to do this but the only thing I can come up with is to drill the hole and use a small file to make it square.
Anyone have a better idea/mousetrap?

Mike

capescw · Post by **capescw** » Mon Jun 25, 2012 6:37 pm

Yes, the square file, but check this first!

http://www.harborfreight.com/air-file-1704.html

I have one, and it's a muscle saver.

Bretto · Post by **Bretto** » Tue Jun 26, 2012 4:50 am

Probably took more time to bring up this site and asks the question then to take a square file the round holes.

I did just what you are asking about. There may be a different solution and for mass production, I suspect they were stamped out but where you just have 2, grab the file.

madmike · Post by **madmike** » Tue Jun 26, 2012 10:37 pm

Sure Bretto but did you look at the tool? I don't have one and I think I'm justified now. But I have to admit I have a square file so thanks guys. I'll do it the hard way.

HULLROAD · Post by **HULLROAD** » Wed Jun 27, 2012 1:15 pm

Just FYI.....if you are just putting them into sheet steel.....and you drill the correct size hole.....you can just pull the bolt up tight and it will force the square into the round hole in the panel. Might not make it past a purist but it does work. If you look close at a lot of NEW carriage bolts the square is actually tapered for that reason.
If you have to have it perfect.....or are pulling it into some thick steel.....the file is the only way.