I've got some steel washers here and I need the diameters of their inner holes to be just 1/16" larger, but my local hardware store doesn't carry any washers of the same outer diameter with larger holes, sooo....

Should I drill 'em out or what? I have to do it in such a way so that the hole remains centered for each washer, so that might make things tricky. The holes are 3/16" and I need them to be 1/4", I'm thinking 1/4" drill bit with a drill press oughta do it, right? Or should I try to widen it with a dremel or something?

HALP PLZ, KTHXBAI

Yeah, you can drill the hole out. I have done this (different size washer/hole, but the concept is the same) with about a 25% yield; that is, I ruined 3 washers for every good one I got. The problem is that when the bit exits the washer, it tends to grab and screws up the washer.

A better bet might be to use a tapered ream to enlarge the hole. You eliminate the drill bit grabbing, and you wind up with a much better internal surface.

On the other hand, have you considered using the "reverse" approach? Get a washer with a 1/4" hole and turn down the outside diameter down to the desired size. Simply mount the washer on a 1/4" bolt (screw) then chuck the screw into a drill and then introduce the (slow) turning washer to a grinding wheel.

Good luck (or just find a better hardware store)

how the hell does a hardware store not carry a washer with a 1/4" hole in the middle?

that is probably one of the most common bolt sizes in the country! I suggest you find a better hardware store that actually sells hardware.

^^^
My compliments to you on your typing/spelling skills. But you really should go back to school (maybe 4th or 5th grade) for reading and comprehension. The OP's issue has to do with the ID/OD ratio of the washer. If you cannot comprehend that concept, get back to me an I'll try to explain it to you in terms you can understand.

I can order pretty much what ever hardware I need, if required for production purposes... There are a few items I purchase which cannot be found in any hardware store you have ever had any knowledge of, but I buy these things in multiples of 10,000 or more at a time. If all you need is a handfull of non-standard washers, all you will ever hope to get is a "let me check and I'll get back to you" with no reasonable expectation of ever hearing from them again.

This is, after all, DIY... my "good hardware store" remark was pretty much tounge in cheek. Or are you new to &totse?

The holes are 3/16" and I need them to be 1/4", I'm thinking 1/4" drill bit with a drill press oughta do it, right? Or should I try to widen it with a dremel or something?



It seems your question of dremel tool use (by hand) removes you from needing a large unit run (thousands of units).
So you don't need thousands of these, is my guess.
I think a drill bit of the desired hole diameter will work well.
More advanced is Phmeworp's advice, which is all good.
G_P's input seems worthy , also.
1/4 inch ID washers with various ODs should be plenty plentiful , it seems.
If not, consider considered using the "reverse" approach , via phmeworp's initial post.

Yeah it's just about 30-40 of these.

I don't know what the deal was with my hardware store, they had every other OD/ID combination except the one I needed.

You could buy the larger washer (with the right sized internal hole) & then machine or grind the outside dia down to size?

phmeworp got it right, the reverse method he suggested is the way to go, it's easier than scratching you ass, and you'll let machines do all the work, you hardly even have to pay attention to what you're doing...
That's the way I do it whenever I need disks/washers/etc. with a smaller OD while keeping the hole centered.
Personally I'd use a belt grinder though, and run the drill as fast as possible (in the opposite direction of the belt, of course), to cut down on work time - time is money you know. ;)

BTW: phmeworp, what do you do for a living?

I am an electronics engineer and own a small manufacturing facility.

I also tinker around lots of other mechanical projects.

^^Damn, fast reply.

Sounds interesting, I work with special effects, so most of what I do revolves around tinkering with mechnical projects...:D

EDIT: Almost forgot, what do you produce?

^^^ The fast reply was a matte of random concidence; I just happened to log back into this thread shortly after your post.

Your suggestion is certainly a most valid one, however, in my experience I have much less luck on belt sanders with metal things than either wood or plastic. But that may be much more due to my skills than any thing else. Again, good suggestion!

Protip for the OP (like you are still reading): Whether you go for enlarging the ID or reducind the OD of the washer... most, if no all, steel washers are plated or coated with something. When you 'modify' either one, you wind up removing whatever protective coating is there. Unless the application you are targeting is COMPLETELY immune to any/all elements, be sure to apply some sort of protective coating to the surface you have modified. That can be as simple as a coat of paint or nail polish (I will not go into having them re-plated), just do something to protect them from the elements.

@SHARP... I am most reluctant to engage in anything that might bear even the most remote resemblance of a thread hijacking. So I am deliberately ignoring your querry regarding products that I manufacture.

Could be an interesting topic if either one of us cares to create a new thread along those lines.

Cheers !

Oh, damn! I didn't read the end of phmeworps post.
So I ended up posting the same idea, duh.

I make belt sanders....& weld.