Reverse chamfer and countersink tool

A tool, comprising:

• a housing having an axis, a generally tubular shape, a bore extending axially through the housing, a cutting opening, a loading opening, an external surface, threads on the external surface, a seat located in the bore, a shoulder located in the bore, and a slot extending axially along the external surface;
• a cutter located in the bore of the housing and being axially and rotationally movable relative to the housing, the cutter having a cutting end, a flange, and a drive feature, the cutter also having a cutting position defined by the flange abutting the shoulder in the bore of the housing such that the cutter is prevented from further axial movement in the direction of the shoulder and the cutting end extending beyond the cutting opening of the housing;
• a snap ring mounted in the seat of the bore of the housing to prevent the cutter from axially exiting the loading opening of the housing;
• a control nut having internal threads and threadingly secured to the threads on the housing such that rotation of the control nut relative to the housing moves the control nut axially relative to the housing, the control nut also having a control end and a lock feature end located opposite the control end, the control nut being axially positioned to adjust an exposure of the cutting end of the cutter beyond the cutting opening of the housing when the control end is located beyond the cutting opening of the housing;
• a staging washer mounted to the external surface of the housing, the staging washer having a bore extending axially therethrough, and a pin extending radially through the staging washer, the pin being located in the slot in the housing to limit rotational movement of the staging washer relative to the housing while allowing axial movement of the staging washer relative to the housing, the staging washer also having a lock feature end, such that engagement of the lock feature ends of the staging washer and the control nut prevents rotation of the control nut relative to the housing, which prevents axial movement of both the staging washer and the control nut relative to the housing;
• and
• a jam nut having internal threads and threadingly secured to the threads on the housing such that rotation of the jam nut relative to the housing moves the jam nut axially relative to the housing, the jam nut being positioned in abutting relation with the staging washer to ensure axial restraint of the staging washer and the control nut when their respective lock feature ends are engaged.

A method of forming a countersink, comprising:

• providing a tool having a cutter and a locking mechanism;
• adjusting the locking mechanism such that the cutter is limited to protrude from the tool and beyond the locking mechanism at a desired dimension;
• securing the locking mechanism from movement relative to the tool;
• positioning the tool adjacent to a workpiece;
• and then
• actuating the cutter relative to the tool and the locking mechanism to form a countersink in the workpiece by inserting a driver into the tool through the cutter and forming the countersink in a direction toward the driver.

A method of forming a countersink, comprising:

• providing a tool having a cutter and a locking mechanism comprising a control nut, a staging washer, and a jam nut;
• rotating the control nut such that the cutter is limited to protrude from the tool and beyond the control nut at a desired dimension;
• sliding the staging washer into engagement with the control nut to prevent rotation of the control nut;
• rotating the jam nut into engagement with the staging washer to prevent axial movement of both the staging washer and the control nut;
• forming a pilot hole in a workpiece;
• positioning the tool adjacent to one end of the pilot hole in the workpiece;
• inserting a pilot through an opposite end of the pilot hole and into the cutter to engage the cutter;
• and
• rotating the cutter relative to the tool by rotating the pilot with a power tool such that the cutter bores into said one end of the pilot hole in the workpiece to form a countersink in the workpiece in a direction toward the power tool.