Making the front spring hole bigger.
 

We are having no luck making the front spring hole better. I have done it previously with a die grinder however we seem to just be eating up bits and not getting anywhere. Suggestions?

What do you need to do this for?

Do you have access to a plasma cutter? You could use one and clean up the cut with a grinder.

For the spring hole to get the spring compressor in it. No access to plasma cutter and sounds like overkill. Only need to make the hole a smidgen bigger.

I used a coarse sanding drum on my dremel. It did the trick in about 8 min.

Would you be able to take before and after pics? What kind of spring compressor are you using? How much is a smidgen in your estimation?:D

I ask these questions because I'm trying to decide if I want to attempt the front end rebuild myself or pay an Indy.

The plate compressor I used was just slightly bigger and a standard round file did the trick with 10mins of grunt work..

this worked for me too. i shortcutted a little by jamming the spring compressor collar in as soon as it would fit and used it to wallow out the hole by puling it to the side and turning it around in biger andbigger circles. made the holes perfectly round and cleaner too

A smidgen was about 1/16" to the hole diameter, or 1/32" around the hole. I used a (borrowed) ebay clone compressor, I'll check the brand tonight.

I used a cone shaped grinding stone from the hardware store in an electric drill. I ran the stone around the inside of the hole with some muscle. I think it took about 5 or 10 min. per hole. Some good hard steel. My El Paso spring compressor fit after this procedure. Took a little paint and touched up the grinding marks.

I used a grinding stone on a dremel, like others, took ~10min per side. I enlarged the hole by ~2mm in diameter. Even though I only needed 1mm for the compressor to fit, I didn't want it to be too tight and jam in the hole at an inconvenient time. On mine, the hole needed to be enlarged only because the laminations of the sheet metal around the hole weren't perfectly registered with each other.

isn't this the tool that if you put it in upside down, it works through the upper spring hole? no grinding needed?

Er? The hole is to small to put the compressor in.

No, if it does not fit one way it will not fit the other. There is only one hole to put it down.

I had the same issue with the two lamination snot being aligned properly that patbob did.

Not on the W123's. Just on the W107's and W114/115's.

I used already worn 1/8" thick by 3-1/2" abrasive cutoff disks on a 1/4" mandrel in a die grinder. They needed to be slightly worn to fit in the hole. Worked like a charm just spinning it in the hole and sliding it up and down.
Die grinder was electric, but air should work if you have enough blast.

Way faster than a dream-el. Mebbe 2 minutes a hole.

Don't forget paint!

--f