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Old 11-14-21, 07:40 PM
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I recently drilled out a thick frozen stem using a hand drill, step bit and extension. This required the stem to be cut off fairly close to the top of the steerer tube. It worked very well, although it's slow and requires cutting oil to resist galling and jamming. Assuming the original hole is centered in the post, the step bit will follow this hole very well and leave you with a thin tube that can be be collapsed by driving a thin screwdriver down the side. The trick might be to come up with a step bit with a suitable maximum size. For the stem, I used a 7/8" bit with the largest step ground off, reducing the maximum size to 13/16 or 20.6mm. For a seat post you would need a 1" step drill, and this size seems to be uncommon.

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