Just use a file. 
Body Question
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Junior User
Joined: Feb 2008
Posts: 61
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From: Moultrie, GA
Body Question
In a bold attempt to put my new tailgate on my 1950 F-1, I found out that the square hole on the truck's body (really stake pocket) needs to be about 1/2 to 3/4 of an inch higher so the tailgate chains will secure it properly. Obviously, I not an expert but I am sure somebody out there knows how I can make square hole. The bolt I will use to attach the chains to the truck is similar to a carriage bolt and needs a square hole. My drill just doesn't seem to do that!
Joker50
Joker50
If you use it, SUPPORT IT
Joined: Sep 2007
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From: Indiana
Or, you can carefully use a body saw or jig saw once you have the hole drilled. They also make air files, that work quite well. Of course, if the hole is real small, just an old hand file is easiest...
R
R
Senior User
Joined: Jul 2006
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From: La Mesa (East San Diego)
If you are doing this in sheet (or metal less than 1/8 inch) try using a dremmel with a cut off wheel to square out the corners. But watch the corners to make sure you don't cut too far. Then file. I actually modified a small square file to fit in my Sawsall for this kind of stuff - I modified a sawsall blade to wrap emery cloth around too. Works great.
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Joined: Oct 2004
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From: Durham NC
I'd use a fine cut slender triangular file to file out the corners square, really only takes a couple minutes per corner. Putting a file handle on the file makes it much easier to use and control. remember a file only cuts on the forward stroke, so release any pressure on it on the return stroke
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Joined: Oct 2004
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From: Durham NC
Not rectangular, triangular (3 sides)! You want one that is ~ 1/4" wide and the cutting surface ~ 6" long with a fine cut pattern. Get a Nicholson or Grobet, don't buy one of the bargain bin made in China crap. They are ~ 6.00 at the hardware store. Handles are ~ 4.00. Mark the square around the round hole, use the corner of the file to file to the corner of the square, then rotate the file so one side is parallel to one side of the square and file away the little nub that's left between the corner and the round hole. Rotate the file the other direction and file the other nub off. Repeat for each corner. Trust me that this is the best and easiest way, I've been filing metal for 37 years! Dremel's can be a very useful tool, but this is not the place to use one IMHO.
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Junior User
Joined: Feb 2008
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From: Moultrie, GA
Excuse me! I had a memory lapse. I picked up a triangular file from my local hardware store for .99 and it worked perfect. I have my new tailgate and chains already attached to my truck. Thank all of you---I am sure I will have more questions.
Joker50
Joker50
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Joined: Jan 2007
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From: Grande Prairie, Alberta
Did the same thing with my running boards. Some of the carriage bolt holes were worn or pulled through. Cut, filled and drilled, the file works slick and takes little time or effort.
If you use it, SUPPORT IT
Joined: Sep 2007
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From: Indiana
I'll agree - it is far easier using a triangle file - you can get much better accuracy over a square file.
R