Not a very bad idea, but it would requier a test bolt. One that has the same fit but no ball. Thusly the bolt would be all metal except the ball would be cut off and a wax ball made on the base of the bolt left over.
This would result in a cast of what the real bolt needs to be. I haven't yet cut the ball.
I want to see what Old Fuff has to say, and review everything he has said.
I am sure he will, but if for any reason he doesn't I can still get this.
What I am mainly interested in is which way to go. Square up the bolt ball or angle it like it is..
I know it is over sized. Making it smaller is a no brainer, but which method is the best?
Your original is squared level with Earth, so is my 1860.
Now I don't know how Old Fuff knows this stuff, but he does. He knows it so well he can type it with out much thought, and it works out, and I can see that he KNOWS.
I know I can make it work, but I want it to be the best you ever had it ... Old Fuff knows how to get that. Me: I'm waiting for a few more words, I am pretty sure he will tell us..
I think this thread is great. I get to learn more, and I belive you are.
That 2nd bolt you had that working awhile. What do you recall about getting that to work?
That bolt was locking on the frame, and caused some of the damage, but it worked right? The ball on that one is bigger than the original by 0.020" heavy, which is midway between numbers on my micrometer as apx 0.0205, almost 0.021"
That figure 0.020 is bigger than old cars with points gap, and not much smaller than old car plug gap.
Taking that much metal off with no cares is a no brainer. Any fool with a grinder can take that and more in a second on any grinder..
So it is a matter of finess to remove a near amount maybe, and have it still take a polish, and not look like a butcher job.
I still have a few tricks waiting.
One is use feeler gauges and see what the distance is between the clyinder in several places, knowing no clyinder is really round; and the frame.
I can and was planning to stick a dob of wax in a cylinder lock slot, not that the one I choose is like any of the others either, and perhaps check a few of the others as well.
That done with the bolt as is.. Have a look at the wax and see if any gets pushed out and where any stays... I assume you are following this line of thought.
If I worked on only things I ever knew before I wouldn't get much work done eh? I have worked on a great deal of things far older than I am. People expect me to know all these things like somehow I should too!
Oh sure I know all about chrystler 331 engines made in 1953 when I was 2. Oh yeah, sure..
That one turned out as who ever wrote the book for these marine engines had no clue. 2 engines, one clockwise, and one counter clockwise in for a total over haul. I mean everything was rebuilt, starters to gennies, carbs to manifolds, everything.
Well that book had the same firing order for both engines. WRONG
I was gifted with a restoration on a 56 Porsche 356 B. I think the B was for bathtub, or something. Anyway I said yes, and that car was in mixed boxes with mixed parts as if a giant dumped all the parts in a refer box, and shook it, then dumped a little bit in about 8 other boxes.
There was 1 piston in each box, and the connecting rods were in other boxes with ft bumper parts, and parts of the trannie were in with interoir parts. Tha whole car was in bits and pieces not just the engine.
I drove that car myself on the test ride. I just love it when no one else wants the job..