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post #1 of 7 Old 10-08-2009, 04:02 PM Thread Starter
Airborne Lee
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carriage bolts?

My trailer lid project would be better off if I was able to use carriage bolts for security reasons also it would smoth out the surface. But how on earth does one make a square hole? is there a tool or does this require a shop with a big punch/press???


'16 JKU Rubicon, Tan, RR Front Bumper, 9500i, Atlas Rear w/Tire Carrier M416 Trailer
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post #2 of 7 Old 10-08-2009, 06:22 PM
Roadymi
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Square peg in a round hole

What material is the head of the bolt going against? If it is plywood or light tin, just drill the hole tight for the threaded part of the bolt. As you tighten the square shoulder will draw into the material and make it's own "square" hole. Just be careful not to over tighten. If the material is heavier steel you will need to have them punched. Most any fab shop with an iron worker and the right die could do it. Or you could get fancy and have them done on a cnc plasma machine.
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post #3 of 7 Old 10-08-2009, 07:33 PM
BESRK
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I've drilled holes and squared them up with a small file. A good sharp file helps. Apply pressure in the cutting direction only to keep from rounding off the teeth and dulling the file.

'80 CJ5 w/AMC360, T176, D44 w/Detroit 4.56, RE 4" YJ lift and 35s..



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post #4 of 7 Old 10-09-2009, 05:16 PM Thread Starter
Airborne Lee
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have you tried a jig saw?

'16 JKU Rubicon, Tan, RR Front Bumper, 9500i, Atlas Rear w/Tire Carrier M416 Trailer
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post #5 of 7 Old 10-10-2009, 09:09 AM
Happy Joe
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For large carriage bolts drill 4 small holes at the corners of the square then drill out the center,with a larger bit, to connect them, file to remove the jaggies.
For small carriage bolts just drill the hole and use a square file to make the corners; as Besrk said.

Enjoy!

'06 TJ Rubicon; seemed like a good idea at the time; had many CJs...
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post #6 of 7 Old 10-10-2009, 10:49 AM
jamm5266
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Searched the web and surprisingly there is actually a way to drill a square hole.

http://upper.us.edu/faculty/smith/reuleaux.htm

Unfortuntely, I don't think this will work with your project.

In your case, I would measure the cross-corner dismension on the square part of the carriage bolt and drill a hole about 1/32" smaller. This should allow the carriage bolt to pull through the material with minimal deforming and stop the bolt from turning freely.

'05 LJ Rubi, starting off with 3" lift and 33 BFG KM2s
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post #7 of 7 Old 10-19-2009, 02:17 PM Thread Starter
Airborne Lee
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Where do I buy this drill bit!!!!!!

For the shear dumb WTF aspect of betting drunk people I can do it.

'16 JKU Rubicon, Tan, RR Front Bumper, 9500i, Atlas Rear w/Tire Carrier M416 Trailer
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