Posted by Tom Fleming on August 09, 2011 at 07:48:50 from (67.20.249.95):
to be honest, 9 times out of 10, I get partway through the drilling and the broken off piece comes loose. Also, it is helpful to start with a drill bit that is 2-3 sizes smaller than the final size for tapping. Work your way up. Patience here is critical, but I have always gotten good results with this method.
I just got done rebuilding the carb for my regular. The idle speed screw broke off flush. It was steel, and the carb is brass. Nightmare thoughts. However, I started with a small drill bit and worked my way up, slowly and patiently. Ended up having to drill to the final size for the tap. Had to buy an uncommon tap size 12-28. All turned out well, and the new screw goes in like a champ.
Bottom line, take your time, drill it out, and retap if necessary. Worst case, you can JB weld a new bushing in there if necessary, or have one brased in if a total melt down occurs with your efforts.
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