Metalworking help

[wlaims]

Wood is so much nicer to work with than metal...

So a while back I bought a Harbor Freight 4x8 utility trailer, with the objective of having something to haul wood with. Finally getting around to assemble it, but ran into a snag:
One of the holes on the trailer isn't lining up, it's off by about 1/4". This is real thick tubular steel stock.

Now I have a well equipped wood shop, but when it comes to metal, all I have is a hacksaw and a few metal files.

How can I hack my way out of the jam?? I don't want to just return the trailer as I already put in a good amount of work assembling half of it and hate to have to start over. I don't mind having an excuse for a reasonably priced tool, but a plasma cutter is out of the question, so you can save that particular suggestion :-)

Any help appreciated...Thanks

[Stytooner]

It happens sometimes. If you can snap a larger picture of the parts this hole is in, that would help. Not real sure from this picture how critical the fix is.
An iron workers tool has a pointed end to help align holes. Make sure all the bolts are loose in the assembly and use perhaps a large phillips screw driver to insert in the holes and try to induce better alignment of the holes.
There are several remedies, but would like to see the big picture.

[LCHIEN]

if its off by 1/4" then looks like those are 1/2" holes?

my off the cuff suggestions:
Have you tightened up other bolts that may not be letting this line up?
loosen all the other bolts and use a line-up tool (basically a long punch like device with a tapered pin end that will be greater than 1/2" diameter at the top of the taper and around 1/4" diameter at the tip) - you should be able to wiggle the line-up tool enough to get the holes to line up and then drop a bolt in it, PROVIDED THERE"S ENUF PLAY IN THE OTHER LOCATIONS. once the bolts are all in thighten them all up.

If there's not really enough play because this hole is off location, then you can open all the other holes and this one up a bit using a 5/8" drill and then do as I suggested above, or, open up this one hole to about 3/4" and use a washer under the bolt. Enlarging a hole is a lot easier than drilling a new large hole; you may have to get a twist bit and you will have to clamp the piece being drilled and get a good grip onthe drill. It will want to grab as you drill through it.

[unknown poster]

You can grind the hole into an oval so things line up better. I would use my die grinder, but a dremel would work similarly.

[leehljp]

Basically what others have said. With HF, I learned to not tighten anything beyond finger tight until all of the bolts and screws are in place, then go back and tighten everything. It is usually a two step procedure for sure.

[RAFlorida]

Agree with the other members about

FINGER tight only. Once all the bolts are in, then tighten. I think this may help you.

[wlaims]

Thanks everyone. Let me give a bit more detail (and will post photos later when I get home):

- The piece in question is the A-frame trailer arm, where the rectangular frame connects to the hitch. It is however foldable and thus swingable.



- The pivot is just a nut, bolt, and a cotter pin keeping everything loose but secured. So not even finger tight, just aligned.
- The other point is a set of aligned holes where we insert a bent lock pin, when the arm is unfolded and locked in place. This is where the holes aren't aligned, and so there is an additional issue of it needing to be loose enough that I can remove/reinsert the lock pin occasionally with ease.



So I think it's harder than the usual case of forcing an alignment so I can insert bolt once. If it comes to enlarging the hole, I didn't think of a dremel. I guess it may take a while and a few bits, but it could work, right?

And are there ways to drill the hole using an 18v cordless hammerdrill? Are there drill bits that may work?

[gjat]

You can easily do it with a hole saw bit. Don't use HF's. Drill it with it folded up so the outside hole lines up the bit.

[RAFlorida]

Your question about the cordless hammerdrill:

As long as you don't have it in "hammer" mode. Other wise the bit will snap.

HSS bits will do the job.

[newbie2wood]

I can't tell from your first picture how the holes are exactly misaligned. Even though the pivot points are loose fitting, your frame may not be square and may be causing the problem at the bent pin locations. If the hole in the A frame piece is to far back (towards the rear of the trailer) in relation to the bracket hole, try the following before you start drilling. Hook up the trailer to your vehicle and give it a tug or pull it for a short distance.
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