Is that a rule I"m not aware of? Didn't know they had a speed limit.

You should really have two handles on the drill. I use the second handle on mine when drilling larger stuff. I've snapped a 1/2 drill bit when it grabbed with no issues using two handles.

 

I'm going to go with the Dremel crowd.

Even better, find someone that's got a good pneumatic die grinder.

You'll probably have a much easier time just shaving away a little bit at a time insead of going out and buying a 7/8" bit, then getting it turned, then drilling that puppy out.

 

I used a cutting burr in my 1/4 air grinder; it took just a few minutes. Whatever you do don't take the suggestion to reduce the OD of the shackle pin. And when you hog out the hole take the material off of the back of the hole so you don't compromise strength in the direction of pull.

 

Actually a 7/8 inch steel drill bit would have a speed limit. In mild steel it would be between 250 and 350 RPM depending on the steel composition and coolant flow. Faster than that and you will burn the edge off the drill in no time. Any cutting tool has a speed and feed limit.

 

go slow and make sure the handle of the drill is already on the bumper and when it grabs, LET IT GO!!!!

 

Makes sense, thanks.

 

not exactly this one but remember those ?Attachment 22162

 

yup i was a machinist for 15 years you can get that bit from your local hardware store!!!as far as the size of the hole you stated .02 difference?thats only 20 thousandths about 4-5 hairs!!!!probably powdercoating in the hole!!

 

Yep, I got out my caliper to check how far off it was, .02 exactly. I think I will try the dremel route first. Hoping that does the trick. I did drill out the light mounting tabs with a 1/2" bit as this hole was a little too small too. That cut like a piece of cake! Since this is a much thicker part, I was a little more cautious about drilling.

 

Definitely not going with a smaller clevis. I want it as heavy duty as possible.