best source for LONG D30 cover bolts?

[Lurch]

I have two RuffStuff covers with the countersunk holes for allen head bolts and I am not a fan. I have broken numerous 3/16" (Craftsman) allen bits off in them trying to get them both on and off. Never went over 30 ft/lbs of torque on the bolts. The look is nice and clean and whatever else it does to add rigidity to the housing is nice, but I hate having to use a damn allen bit to get them off.

I would go for a cover that uses regular hex cap bolts if I were to do it over again.

 

[kastein]

For once I see a reason to put Torx bolts on something.

 

[jeeperjohn]

Agreed. Just gotta get them right on center or you'll be fighting to get the bolts in and torqued without it warping and trying to move around on you.

You have to do it with a piloted countersink. You can get them at Brown aviation tools.

 

[5-90]

I have two RuffStuff covers with the countersunk holes for allen head bolts and I am not a fan. I have broken numerous 3/16" (Craftsman) allen bits off in them trying to get them both on and off. Never went over 30 ft/lbs of torque on the bolts. The look is nice and clean and whatever else it does to add rigidity to the housing is nice, but I hate having to use a damn allen bit to get them off.

I would go for a cover that uses regular hex cap bolts if I were to do it over again.

Screws are probably seizing in the holes - common, when you're working undercar.

Coat the threads with RTV before you put them in. Double duty - it helps to keep the screws in place, and it does a better job of preventing seizure than LocTite does. (PTFE paste will also work.)

 

[Vanimal]

unless the surface is uneven, you can float the cover in a drill press and use a regular countersink of the correct angle. it's going to follow the hole. the lower the rpm's the better, the less flutes on the countersink the better, i usually use single flute ones. a little oil, constant pressure.

as for using stainless, i had issues with my bolts loosening up with any solid hits to the diff cover. it happened twice in a few month period before i ditched the axle.