broken carb needle removal

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Mechanic stripped the slot head of a needle jet in a outboard motor carb. I tried to die grind new slot with burr- no go. Welded stub on screw head tried to unscrew, it broke wayyy down a 8mm counterbore. Oh for joy! Tried 1 inch gas cup, .040 red tungsten sticking way too far out, .035 stainless filler. Arced to sides of bore, contaminated tungsten. touched tungsten with filler- contaminated some more! Tihs turned out to be a pain, couldn't see what I was doing. Ugly as hell, but I managed to glob on some filler. Used Vice Grip on stub- success! Unsecrewed. Threads intact, counter bore ugly but won't effect function. Tomorrow two brake calipers with 4 stuck allen head screws, hex bores rounded off. Oh for Joy!Oh- everything is black in weld area because   1- I kept contaminating tungsten   2- touched wax to area while hot.Peter Attached Images
Reply:Yeah man! I had to dig the tips of needles out of my Mikuni 27mm quad/carbs before with a dentalpick...no fun!!  Good job getting that bugger out!City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:A lesser man would have smashed the carb in a fit of rage in order to remove the jet
Reply:why didnt you sleeve the hole with a thin piece of copper tubing so the aluminium would not be messed up???
Reply:That is an amazing save, excellent, but ugly.
Reply:I only wish I had patience like you! Great save
Reply:Originally Posted by tanglediverYeah man! I had to dig the tips of needles out of my Mikuni 27mm quad/carbs before with a dentalpick...no fun!!  Good job getting that bugger out!
Reply:Peter:Thanks for showing the 'hard stuff'. I might have removed the carb, with something heavy.   "Just walk away and sleep on it" means more now than when I was younger.9-11-2001......We Will Never ForgetRetired desk jockey. Hobby weldor with a little training. Craftsman O/A---Flat, Vert, Ovhd, Horz. Miller Syncrowave 250
Reply:Peter;I've resisted all day, but just can't any longer....Why, after you finally got the needle out, didn't you mill the hole a bit wider so ....You'd have more room to work ...Next Time!                           I'm sorry!
Reply:Originally Posted by Oldiron2Peter;I've resisted all day, but just can't any longer....Why, after you finally got the needle out, didn't you mill the hole a bit wider so ....You'd have more room to work ...Next Time!                           I'm sorry!
Reply:You mean there actually could be a next time for the same carb?Seriously, though; I was curious about what you thought caused the original (I assume) binding. Corrosion, perhaps from water getting in the carb, or maybe alcohol in the fuel?Too busy to even worry about it?
Reply:Originally Posted by Oldiron2You mean there actually could be a next time for the same carb?Seriously, though; I was curious about what you thought caused the original (I assume) binding. Corrosion, perhaps from water getting in the carb, or maybe alcohol in the fuel?Too busy to even worry about it?
Reply:I have been wanting to ask you........Exactly what type of business are you in?  Seems like you always get the jobs that nobody else wants or can do.
Reply:Having looked at all his posts.  He's in the business of either save it cheap, or save it at all costs.Either way, it's a save, and it's what the customers keep coming back for, or tell others of the magic.What with the economy getting worse....... I hope it gets back to true mechanics.  Not just throw away and replace mechanics.  The guys that can take a ruined thing and make it right without junking the entire casting or other part."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Originally Posted by busymanI have been wanting to ask you........Exactly what type of business are you in?  Seems like you always get the jobs that nobody else wants or can do.
Reply:You got that right.....BrandonLincoln Tombstone 225 A/C Steel StickerOld Victor O2/Acetylene setupMiller Syncrowave 250 Tig/PC-300 PulserMiller Millermatic 212 Mig HTP Invertatig 201 Giant Teck D50 Plasma cutterLots of HF grinders