Good progress. Having the right tools at the right time sure does help. Or friends with them.
A sand or bead blasting cabinet sure would be nice for the rusty, corroded stuff.
If you've never used Evapo-Rust you'd be amazed at how it works versus electrolysis. I cannot say more. Electrolysis to remove the crust and then a soak in it would bring big smiles.
Kroil. You gotta' get a can of Kroil!
Helicoil kits are not too expensive for a one-off fix. They don't overbore much compared to a drill to the next size up. Or....and friend with a Time-Sert kit.
The old mig or tig a nut to broken studs and bolts works wonders. Sometimes, usually.
Drilling into twisted off hardware and making sure the pilot hole is centered is a pain. The bolt or stud becomes work hardened in the exact place you need to drill. Sucks!
A steel or copper sleeve slipped over the protruding threads or inside of a recessed bore. Perhaps telescoping another piece inside. Makes for a drill guide that should let you start the pilot hole centered.
Those diamond Dremel-type cutter bit assortments you see in hardware stores are awesome. Using the above sleeve guide you will be able to grind a starter hole right smack in the center. Let the diamond do the work. Squirt cooling water to flush the cuttings. A small set of end mills using the same procedure works.
That last photo of the mounting flange would be handled well with a small bearing knife. I have a set from small to large. Really makes pulling a tough CV axle from vehicles quick work.
Too bad you don't have a hobbiest powder coat rig and able to send the wifey out while you steal her oven for a bit!
Good job!
