Oddjob
Merry fucking Xmas to you assholes
Also a notable postscript to this story. The Ultegra BBR60 that I originally fitted to the bike is still running silky smooth. This is after 8 years and god knows how many watts and kms that it's seen. All this for 1/5 of the cost of the equivalent CK bb.Almost ended up in the fuckwits thread, but ended up feeling really good about my investment in tools over the years.
My main roadie is about 8 years old now and hasn't had a proper service since I built it. The original carbon fork had an alloy steerer which I was starting to get worried about. My integrated bar/stem was also starting to lose paint around the alloy stem section so I decided to give the bike a full refresh.
My Lynskey Sportive disc was right at the end of straight steerer era, so sourcing a new carbon disc fork was hard. Managed to get a Carver full carbon fork that was advertised as being 150gms heavier than it's predecessor, and looking at the amount of material in the steerer you can see they were aiming for strength above all else. Fitted the new fork and full carbon bar/stem combo now problem. Serviced and bled the brakes and replaced the cables.
Then went to refit the mudguards to the fork. Started to wind in the m5 bolt into the leg eyelet. Hmm this is a bit stiff, they probably didn't chase the threads. Then I literally twisted the head off the bolt with 6mm of the bolt shaft showing. Normally I leave the tricky jobs to the former F1 engineer who co-owns the lbs, but of course the lbs is shut for lockdown. Uh oh.
My first plan of attack was to use an adjustable gripjaw, no joy. Next was to dremel a slot into the shaft and use a flathead screwdriver. Nope. Dremel a cross slot. Nope. Out comes the Milwaukee drill, first I break a Hitachi 2.5mm drill bit, then a 3mm drill bit. Finally find a Sutton 3mm hss drill bit that makes some headway. Spend 20 mins drilling through the bolt in the hope of chipping out the bolt. Nope. Have a brainwave to use an easy out. It works!
I then use a 5mmx0.8 thread tap to clean up the threads in the eyelets and they are unsurprisingly gunky. Ponder whether I should have started with this step. Anyway final result is below. The old girl scrubbed up pretty well.
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Sent from my SM-G970F using Tapatalk