Reusable Liquid Metal Castable Drill Bushing Assembly and Method

A method of locating hole features so that old components can be replaced with new components, the method comprising:

• adhering a bushing assembly into a fixture plate, the bushing assembly comprising:
• a cylindrical sleeve having an inner diameter;
• a cylindrical drill bushing having an outer diameter, the cylindrical drill bushing disposed within the cylindrical sleeve;
• a liquid metal disposed between the inner diameter of the cylindrical sleeve and the outer diameter of the cylindrical drill bushing;
• a seal disposed on the cylindrical sleeve, the cylindrical drill bushing, and the liquid metal such that the seal retains the liquid metal between the outer diameter of the cylindrical drill bushing and the inner diameter of the cylindrical sleeve;
• rigidly attaching the fixture plate with the bushing assembly to an old component;
• heating the liquid metal above the liquid metal melting temperature such that the cylindrical drill bushing can move within the bushing assembly;
• inserting an alignment pin within the cylindrical drill bushing such that the alignment pin is also inserted into an existing hole in the old component;
• allowing the liquid metal to re-solidify;
• and,
• using the assembly as a drill guide for replacing holes in a new work component.