Bilco Tools Inc.

Technical Reference Manual

TM

Tough Boy Combination Tool

Description / Application
TM
The Bilco Tough Boy Combination Tool is dressed
with scraper blades which lead and brush elements
which trail. This configuration provides the scratch and
scour effect necessary to prepare casing and liner ID’s
in certain applications. The scraper blades provide 360-
degree coverage. The brush elements provide 360-
degree coverage. Bilco Combination Tools will add
value to your clean-out displacement string by
eliminating the amount of tool bodies without
sacrificing the desired effects.

Operation
TM
The Bilco Tough Boy Combination Tool is
recommended for short casing or liner lengths were
there will not be any packer setting requirements. It
may be run as a stand alone device in the drill string.
The same Bilco toughness and reliability are built into
TM
every tool. Bilco Tough Boy Combination Tools are
compatible with the entire line of Bilco Wellbore Clean-
out Tools.

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 Bilco Tools Inc.
Technical Reference Manual
Field Handling Guidelines
TM
Tough Boy BRUSH TOOL

OPERATING GUIDELINES AND TOOL PLACEMENT

TM
 The Tough Boy Combination Tool is designed to be run as a stand alone device in the drill string.
 Designed to be run in short casing of liner lengths were there is no packer setting requirements.
 Compatible with the entire line of Bilco Well Bore Clean-out Tools.

FIELD HANDLING GUIDELINES

 Screw lifting cap into tool on pipe rack or catwalk to move tool to rig floor. Do not sling tool
around brush blades.
 Place tool on stump at rotary, install proper crossover on drill pipe, screw into tool, lower tool into
hole and torque connection using snub line to prevent tool damage.
 If more than one Bilco tool is utilized in the same string placement it is recommended that this sub
assembly be pre-built at the shop to save rig time.
 If tools or assemblies are too long, the mouse hole may be used to make connection provided a snub
line is used.
 Ensure proper lifting equipment and tag lines are utilized when moving pre built assemblies to the
rig floor
 The tool or assemblies should be broken out and laid down using the same general handling
procedures used during pick up and make up, except in reverse order.
 Prior to running a single tool or assemble the bore should be drifted to ensure that it is clear of any
obstruction.
 If there is any doubt about the tools fitness for use, a replacement should be requested from Bilco
Tools Inc or its authorized agent.
 The tool should be returned to Bilco using the same cradle, basket, and thread protectors that were
originally supplied.

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Technical Reference Manual
Operating Parameters
TM
Tough Boy COMBINATION TOOL
Patented

Units in English System

Operational Parameters for Combo Brush Scraper

Tool Size Trip Speed Rotating Speed Circulating Rates

4 1/2" - 5” 150 ft/min 60 rpm LIMITED
5 1/2" 150 ft/min 80 rpm ONLY
6 5/8” - 7 5/8” 150 ft/min 100 rpm BY
8 5/8” - 11 3/4" 150 ft/min 100 rpm SURFACE
13 3/8” - 20” 150 ft/min 100 rpm EQUIPMENT

Connection and Tool Body Torsional and Tensile Yield Strengths

Connection
Yield Body Torsional Body Tensile
Connection Make Up Torque Tensile
Strength Yield Strength Yield Strength
Yield Strength
2 3/8” reg 3,000 - 3,500 ft-lbs 5,329 ft-lbs 344,416 lbs > 5,250 ft-lbs 345,600 lbs
2 7/8” reg 6,000 - 7,000 ft-lbs 10,508 ft-lbs 546,827 lbs >10,500 ft-lbs 437,416 lbs
3 1/2" reg 7,000 - 9,000 ft-lbs 15,141 ft-lbs 762,886 lbs >13,500 ft-lbs 773,148 lbs
3 1/2" IF 10,000 - 11,500 ft-lbs 19,174 ft-lbs 1,046,231 lbs >27,000 ft-lbs 1,531,525 lbs
4 1/2" reg 15,000 - 18,000 ft-lbs 29,906 ft-lbs 1,311,422 lbs >27,000 ft-lbs 1,531,525 lbs
4 1/2" IF 23,000 - 26,500 ft-lbs 44,166 ft-lbs 1,742,488 lbs >39,750 ft-lbs 1,531,525 lbs
6 5/8” reg 50,000 - 58,000 ft-lbs 97,351 ft-lbs 2,098,526 lbs >87,000 ft-lbs 2,803,960 lbs
4" HT-38 15,000 - 17,000 ft-lbs 25,000 ft-lbs 587,300 lbs >25,500 ft-lbs 773,148 lbs
4" HT-40 12,000 - 17,000 ft-lbs 28,500 ft-lbs 407,600 lbs >25,500 ft-lbs 773,148 lbs
4 1/2" XTM-40 17,000 - 26,200 ft-lbs 43,600 ft-lbs 816,400 lbs >39,300 ft-lbs 1,091,280 lbs

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 Bilco Tools Inc.
Technical Reference Manual
Operating Parameters
TM
Tough Boy COMBINATION TOOL
Patented

Units in SI System

Operational Parameters for Combo Brush/Scraper

Tool Size Trip Speed Rotating Speed Circulating Rates

4 1/2" - 5” 46 m/min 60 rpm LIMITED
5 1/2" 46 m/min 80 rpm ONLY
6 5/8” - 7 5/8” 46 m/min 100 rpm BY
8 5/8” - 11 3/4" 46 m/min 100 rpm SURFACE
13 3/8” - 20” 46 m/min 100 rpm EQUIPMENT

Connection and Tool Body Torsional and Tensile Yield Strengths

Connection
Yield Body Torsional Body Tensile
Connection Make Up Torque Tensile
Strength Yield Strength Yield Strength
Yield Strength
2 3/8” reg 407 - 475 daN.m 723 daN.m 153,196 daN > 712 daN.m 153,723 daN
2 7/8” reg 814 - 949 daN.m 1,425 daN.m 243,229 daN > 1,424 daN.m 194,563 daN
3 1/2" reg 949 - 1,220 daN.m 2,053 daN.m 339,332 daN > 1,831 daN.m 343,896 daN
3 1/2" IF 1,356 - 1,559 daN.m 2,600 daN.m 465,364 daN > 3,661 daN.m 681,222 daN
4 1/2" reg 2,034 - 2,441 daN.m 4,055 daN.m 583,321 daN > 3,661 daN.m 681,222 daN
4 1/2" IF 3,119 - 3,593 daN.m 5,989 daN.m 775,059 daN > 5,390 daN.m 681,222 daN
6 5/8” reg 6,780 - 7,865 daN.m 13,201 daN.m 933,424 daN >11,797 daN.m 1,247,201 daN
4" HT-38 2,034 - 2,305 daN.m 3,390 daN.m 261,231 daN > 3,458 daN.m 343,896 daN
4" HT-40 1,627 - 2,305 daN.m 3,865 daN.m 181,300 daN > 3,458 daN.m 343,896 daN
4 1/2" XTM-40 2,305 - 3,553 daN.m 5,912 daN.m 363,135 daN > 5,329 daN.m 485,401 daN

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Technical Reference Manual
Model Number Reference Chart
TM
Tough Boy COMBINATION TOOL

Weight 2-3/8” 2-7/8” 3-1/2” 3-1/2” 4-1/2” 4-1/2” 4” 4” 4-1/2” 3-1/2” 6-5/8”
Casing Range in Reg. Reg. Reg. IF Reg. IF HT-38 HT-40 XTM-40 XH Reg.
Size lbs/ft B x P B x P B x P B x P B x P B x P B x P B x P B x P B x P B x P
4 1/2” 9.5 – 13.5 BT-450-0AC-1
11.5 – 18.0 BT-500-0AC-1
5” 20.3 – 26.7 BT-450-0AC-1
14.0 – 23.8 BT-550-0AC-1
5 1/2” 26.0 – 32.6 BT-500-0AC-1
6 5/8” 20.0 – 32.0 BT-662-0AC-1
17.0 – 29.0 BT-700-0AC-1 BT-700-0AC-3 BT-700-0AC-3
7” 32.0 – 44.0 BT-662-0AC-1
24.0 – 33.7 BT-762-0AC-1 BT-762-0AC-4 BT-762-0AC-5
7 5/8” 39.0 – 55.3 BT-700-0AC-1 BT-700-0AC-3 BT-700-0AC-6
24.0 – 49.0 BT-862-0AC-1
8 5/8” 58.7 – 77.1 BT-762-0AC-1 BT-762-0AC-4 BT-762-0AC-5
40.0 – 53.5 BT-962-0AC-2A BT-962-0AC-1 BT-962-0AC-2B
9 5/8” 53.5 – 64.9
9 7/8 62.8 BT-962-0AC-2A BT-962-0AC-1 BT-962-0AC-2B
32.7 – 55.5 BT-107-0AC-1
10 3/4” 79.2 – 109.0 BT-962-0AC-2A BT-962-0AC-2B
42.0 – 71.0 BT-117-0AC-1
11 3/4" 71.0 – 87.2 BT-117-0AC-1
13 3/8” 48.0 – 86.0 BT-133-0AC-1
16” 65.0 – 146.0 BT-160-0AC-1
20” 94.0 – 187.0 BT-200-0AC-1

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 Bilco Tools Inc.
Technical Reference Manual
Model Numbers
TM
Tough Boy Combination Tool

Model Number Description

Tough BoyTM Brush Tool for 41/2" 9.5# - 16.9# 3.5 OD stabilizer w/ 2 3/8 reg
BT-450-OAC-1 Box X Pin - .875" ID
Tough BoyTM Brush Tool for 5" 11.5# - 20.3# 4.009 OD stabilizer w/ 2 3/8 reg
BT-500-OAC-1 Box X Pin - 1" ID
Tough BoyTM Brush Tool for 5 1/2" 14# - 23# 4.495 OD stabilizer w/ 2 7/8 reg
BT-550-OAC-1 Box X Pin - 1" ID
Tough BoyTM Brush Tool for 7" 17# - 29# 5.900 OD stabilizer and 32# - 35# 5.75 OD
BT-700-OAC-1 stabilizer w/ 3 1/2 reg Box X Pin - 1.25" ID
Tough BoyTM Brush Tool for 7" 17# - 29# 5.900 OD stabilizer and 32# - 35# 5.75 OD
BT-700-OAC-3 stabilizer w/ HT-38 Box X Pin - 1.25" ID
Tough BoyTM Brush Tool for 7" 17# - 29# 5.900 OD stabilizer and 32# - 35# 5.75 OD
BT-700-OAC-6 stabilizer w/ 3 1/2 XH Box X Pin - 1.25" ID
Tough BoyTM Brush Tool for 7 5/8" 26# - 39# 6.4 OD stabilizer w/ 3 1/2 reg
BT-762-OAC-1 Box X Pin - 1.25" ID
Tough BoyTM Brush Tool for 7 5/8" 26# - 39# 6.4 OD stabilizer w/ HT-40
BT-762-OAC-4 Box X Pin - 1.25" ID
Tough BoyTM Brush Tool for 7 5/8" 26# - 39# 6.4 OD stabilizer w/ XTM-40
BT-762-OAC-5 Box X Pin - 1.25" ID
Tough BoyTM Brush Tool for 8 5/8" 36# - 49# 7.30 OD stabilizer w/ 4 1/2 reg
BT-862-OAC-1 Box X Pin - 2.0" ID
Tough BoyTM Brush Tool for 9 5/8" 40# - 53.5# 8.33 OD stabilizer w/ 4 1/2 reg
BT-962-OAC-1 Box X Pin - 2.0" ID
Tough BoyTM Brush Tool for 9 5/8" 40# - 53.5# 8.33 OD stabilizer w/ 4 1/2 IF
BT-962-OAC-2 Box X Pin
Tough BoyTM Brush Tool for 10 3/4" 65.7# - 71# 9.5 OD stabilizer w/ 4 1/2 reg
BT-107-OAC-1 Box X Pin - 2.0" ID
Tough BoyTM Brush Tool for 11 3/4" 42# - 71# 10.4 OD stabilizer w/ 4 1/2 reg
BT-117-OAC-1 Box X Pin - 2.0" ID
Tough BoyTM Brush Tool for 13 3/8" 61# - 80.70# 12.00 OD stabilizer w/ 6 5/8 reg
BT-133-OAC-1 Box X Pin - 2.50" ID
Tough BoyTM Brush Tool for 16" 65# - 109# 14.450 OD stabilizer w/ 6 5/8 reg
BT-160-OAC-1 Box X Pin - 2.50" ID
Tough BoyTM Brush Tool for 20" 94# - 133# 18.50 OD stabilizer w/ 6 5/8 reg
BT-200-OAC-1 Box X Pin - 3.0" ID

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 Bilco Tools Inc.
Technical Reference Manual
Dimensional Chart

Combination Tool
(all dimensions in inches)
A B C D E F G
Brush Blades
Model Number Pin OD Cap OD Ext. Extended Box OD Bore Body OD
BT-450-OAB-1 3.1250 3.5000 4.0620 4.1250 3.1250 0.8750 3.5000
BT-500-OAB-1 3.1250 4.0090 4.0620 4.6250 3.1250 1.0000 3.7500
BT-550-OAB-1 3.7500 4.4950 5.5000 5.1875 3.7500 1.0000 4.2500
BT-700-OAB-1 4.2500 5.9000 6.8120 5.8750 4.2500 1.2500 5.1250
BT-700-OAB-3 4.2500 5.9000 6.8120 5.8750 4.2500 1.2500 5.1250
BT-700-OAB-6 4.2500 5.9000 6.8120 5.8750 4.2500 1.2500 5.1250
BT-762-OAB-1 4.2500 6.4000 7.4370 6.5000 4.2500 1.2500 5.1250
BT-762-OAB-4 4.2500 6.4000 7.4370 6.5000 4.2500 1.2500 5.1250
BT-762-OAB-5 4.2500 6.4000 7.4370 6.5000 4.2500 1.2500 5.1250
BT-862-OAB-1 5.5000 7.3000 8.1870 7.6250 5.5000 2.0000 6.7500
BT-962-OAB-1 5.5000 8.3300 9.1870 8.3750 5.5000 2.0000 6.7500
BT-962-OAB-2 5.5000 8.3300 9.1870 9.3750 5.5000 2.0000 6.7500
BT-107-OAB-1 5.5000 9.5000 10.5000 9.5625 5.5000 2.0000 8.5000
BT-117-OAB-1 5.5000 10.4000 11.3750 10.3125 5.5000 2.0000 8.5000
BT-133-OAB-1 7.7500 12.0000 13.0000 11.9375 7.7500 2.5000 10.0000
BT-160-OAB-1 7.7500 14.4500 15.5000 13.3750 7.7500 2.5000 10.0000
BT-200-OAB-1 7.7500 18.5000 21.0000 17.5000 7.7500 3.0000 14.0000

B
D
G

F
E
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 Bilco Tools Inc.
Technical Reference Manual
REDRESS PROCEDURES
TM

Tough Boy COMBINATION TOOL

I. Disassembly Procedures.

A. Visually inspect all Combination Tools & subs and then fill out Check-in Sheet (see page 14).
Inspect for missing or damage to:
1. Tool body
2. Brush Fixtures
3. Scraper Blades
4. Socket Head Cap screws
5. Blade Retainer Cap Halves
6. Thread protectors
7. If there is an abnormal amount of damage, depending on severity a third party should be
performed. Mark the Combination Tool and hold until the customer is contacted and settlement
is arranged.
B. Disassemble Combination Tool. Remove:
1. Socket Head Cap screws
2. Blade Retainer Cap Halves
3. Brush Fixtures
4. Scraper Blades
5. Scraper Blade Springs
6. Thread protectors
C. Prepare for Inspection by removing rust, paint, etc…
D. Have third party inspection service perform thorough inspection:
1. M.P.I.
2. Threads & Shoulders
3. Bore
4. Brush Fixtures
5. Scraper Blades
6. Blade Retainer Cap Halves
7. Check Blade and Blade Slot dimensions to ensure all measurements are within acceptable
tolerances. (See Tolerance Chart for Blade Slots and Blades page 12.)
E. Body damage
1. If the Combination Tool passes inspection:
a. Prime, paint, coat threads with protectant, install thread protectors, and place into rental
inventory.
2. If the Combination Tool fails the inspection:
a. Mark and label the Combination Tool as to how it failed inspection.
(1) If it is repairable, the Combination Tool is sent to a machine shop for repair.
(2) If the Combination Tool is not repairable (cracked, too short, or worn blade slots), mark
the tool and hold it for discarding.
Combination Tools to be discarded are cut in half before being discarded.

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Technical Reference Manual
REDRESS PROCEDURES
TM

Tough Boy COMBINATION TOOL

Continued

F. Blade Retainer Cap Halves; clean and inspect.

1. Clean.
2. Check threads.
a. If threads are OK, prime, paint cap and place into rental inventory. Painting constitutes
proof that the cap meets all inspection requirements.
b. If threads fail inspection, discard the cap.
G. Brush Fixture; remove brushes, clean brush fixtures, and inspect for cracks. If a brush fixture is
cracked discard the brush fixture and replace.
H. Springs
1. Coil Springs – replace after each use.
2. Leaf Springs – replace after each use.
I. Scraper Blades; clean and inspect.
1. If there are no visible wear indicator holes in the blades discard and replace the blades.
2. Check the foot of each blade for cracks or excessive wear. Discard any blade that has cracks or
any blades that show excessive wear on the foot.
J. Clean and inspect socket head cap screws.
1. If socket head cap screws pass inspection, place screws into rental inventory
2. If the threads are galled, shows signs of stress, or the socket head is damaged (rounded out),
discard the screw and replace.

I. Assembly Procedures.

A. In order to assemble Combination Tools to specified requirements, acquire the size and weight of
casing to verify casing ID and drift. Refer to Model Number Reference Chart. (see page 5). Drift
size is needed to determine the size of scraper blades.
B. Gather the supplies needed to assemble the Combination Tool.
1. Gather the supplies needed as per Redress Kit for particular model number. Ensure that all
components (body, brush fixtures, blades, stabilizer retainer cap, etc…) have passed M.P.I.
inspections.
C. Assembling Combination Tools:
1. Determine the minimum O.D. and maximum O.D. of the leading scraper blades used in the
Combination Tool.
a. Set the blades on a flat surface. Use the tallest blade to calculate minimum and maximum
outside diameters.
b. Using a caliper and precision scale (with capabilities of measuring in 1/32 nds of an inch),
determine the O.D. of the Combination Tool body in the blade area.
c. Insert the blade found in step a into a bottom blade slot and measure the distance from the
outside of the scraper body to the highest point on the cutting side of the blade. This is the
min. measurement.

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Technical Reference Manual
REDRESS PROCEDURES
TM

Tough Boy COMBINATION TOOL

Continued

(1) Note: use a spring allowance of 4/ 32”. This spring allowance is a safety measure.
body size + min. measurement + min. measurement +spring allowance = Minimum O.D.
Example: 5 4/32 + 3/32 + 3/32 +4/32 = 5 14/32 = 5.4375
d. Pull the blade into the fully extended position and measure the distance from the scraper
body to the highest point on the cutting side of the blade to obtain the max. measurement.
body size + max. measurement + max. measurement = Maximum O.D.
Example: 5 4/32 + 19/32 + 19/32 = 6 10/32 = 6.313
SCRAPER MINIMUM O.D. + .250” = MINIMUM DRIFT THAT THE TOOL SHOULD BE RUN IN TO.
TM
e. Record the tool’s serial number, all measurements and all calculations on the Tough Boy
Combination Tool Spec. Sheet (see page 13). Record the serial number, the minimum O.D.,
and the maximum O.D. information on a label and install the label on the fish neck section
of the tool’s body above the stenciled serial number. Apply clear tape over label to protect
label.
2. Springs:
a. For Leaf Springs: Apply some grease in all blade slots. Place a leaf spring into a blade slot
with the radius of the spring facing out and slide an appropriate blade into the slot on top of
the spring. Repeat for all blades.
b. For Coil Springs: Place a spring into the first spring hole in the bottom side of the blade
and slide partially into the blade slot. Add one spring at a time while inserting blade into
slot. Make sure all springs are straight. Repeat for all blades.
3. Apply grease to the area on Combination Tool body where the Blade Retainer Cap will be
installed.
4. Check Model Number Reference Chart and Redress Kit Specifications for proper size brush
elements.
5. Insert brush fixtures (with brush elements installed) and brush element keepers into the top slots
one at a time while using a blade retainer cap halve to keep brush fixtures from falling out
during the installation.
6. Apply some thread locking compound to the bottom threads on all of the socket head cap
screws, and insert them into the blade retainer cap halves. (Bilco recommends the use of
stainless steel nylock socket head cap screws).
7. Tighten screws. (see torque values in the “Recommended Torque for SHCS” chart below)

Recommended Torque for SHCS

Tool Size Bolt Diameter Allen Size Torque for SHCS
4 1/2” - 5” 3/8” 5/16” 35 ft-lbs
5 1/2” 7/16” 3/8” 55 ft-lbs
7” - 7 5/8” 1/2" 3/8” 81 ft-lbs
8 5/8” - 9 5/8” 9/16” 1/2” 117 ft-lbs
10 3/4” - 16” 5/8” 1/2” 166 ft-lbs
20” 3/4" 5/8” 288 ft-lbs

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Technical Reference Manual
TM
Tough Boy COMBINATION TOOL MAINTENANCE SHEET
BILCO COMBINATION TOOL MAINTENANCE:

Remove the socket head cap screws (Fig. E) from the blade retainer cap (Fig. B). Then, tap the two halves of cap from
combination tool body (Fig. A). Slide Brush Fixtures (Fig. C) & Scraper Blades (FIG. CL) towards center of combination tool’s
body where the caps were removed. NOTE: WHEN BRUSH FIXTURES SLIDE OUT, BRUSH ELEMENT KEEPERS (FIG.
CK) MAY FALL OUT & WHEN SCRAPER BLADES SLIDE OUT, SCRAPER BLADE SPRINGS (FIG. DL or DC) MAY
FALL OUT. Clean all parts. Remove Brush Elements from Brush Fixtures.

Combination Tool Inspection: should be inspected (M.P.I.) on the entire length of tool’s body including blade slots and brush
fixture slots. If combination tool body is cracked it should be discarded. Threads & shoulder should be inspected for damage.
Damaged threads or shoulder should be repaired or re-cut as necessary. Brush fixtures and scraper blades should be inspected
for cracks. If a Brush fixture or scraper blade is cracked, discard and replace.

To reassemble Combination Tool: Blades with leaf springs, place a reasonable amount of grease in spring and blade slot. Place
spring (Fig. D) in slot with bow of spring outward. Press spring slightly downward and slide blade (Fig. C) in slot until blade is
over spring enough to slide completely into scraper body. Blades with coil springs, grease is not necessary. Insert first spring
(Fig. DC) into blade and insert blade (Fig. CC) partially into scraper. Install springs one at a time while inserting blade into slot.
After blade is completely installed, make sure springs are straight. Insert new brush elements (Fig. D) into brush fixtures (Fig.
C). While holding brush element keeper (Fig. CK) against the bottom of the brush fixture (Fig. C), insert into combination tool
body (Fig. A). Install the two blade retainer cap halves (Fig. B) onto combination tool body and install socket head cap screws.
Tighten the socket head cap screws (Fig. E) with allen wrench (Fig. F).
Fig. A

Fig. B
Fig.
A – Combination Tool Body
Fig. C
B – Blade Retainer Cap Halves
C – Brush Fixture
Fig. CK
CK – Brush Element Keeper
D – Brush Element Fig. D
CL – Scraper Blades - Leading
DL – Scraper Blade Spring - Leaf Fig. CL
DC – Scraper Blade Spring - Coil
E – Socket Head Cap Screws
F – Allen Wrench Fig. DL

Fig. DC

Fig. E

Fig. F

NOMINAL ASSEMBLED RETAINER BRUSH ELEMENT BRUSH BLADES SPRINGS SPRINGS SOCKET HEAD ALLEN
SIZE TOOL CAP FIXTURES KEEPERS ELEMENTS LEADING LEAF COIL CAP SCREW WRENCH
Fig.(A) Fig. (B) Fig.(C) Fig.(CK) Fig.(D) Fig. (C) Fig. (D) Fig. (DC) Fig. (E) Fig.(F)
4-1/2 ........ BT-450-OAC........ BT-500-A2....... BT-600-A4 ....... BT-601-A8.......... BT-700-A24........ BT-450-CL4 ........ BT-100-D4 ....... BT-100-DC16 ....... BT-100-E4........ BT-100-F1
5 .............. BT-500-OAC........ BT-500-B2 ....... BT-600-A4 ....... BT-601-A8.......... BT-700-B24 ........ BT-450-CL4 ........ BT-100-D4 ....... BT-100-DC16 ....... BT-100-E4........ BT-100-F1
5-1/2 ........ BT-550-OAC........ BT-500-C2 ....... BT-600-B4 ....... BT-602-B8 .......... BT-700-C24 ........ BT-550-CL4 ........ BT-200-D4 ....... BT-200-DC16 ....... BT-200-E4........ BT-200-F1
7 .............. BT-700-OAC........ BT-500-D2....... BT-600-C4 ....... BT-603-C8 .......... BT-700-D24........ BT-700-CL4 ........ BT-300-D4 ....... BT-300-DC16 ....... BT-300-E4........ BT-300-F1
7 .............. BT-700-OAC........ BT-500-E2 ....... BT-600-C4 ....... BT-603-C8 .......... BT-700-D24........ BT-700-CL4 ........ BT-300-D4 ....... BT-300-DC16 ....... BT-300-E4........ BT-300-F1
7-5/8 ........ BT-762-OAC........ BT-500-F2 ....... BT-600-C4 ....... BT-603-C8 .......... BT-700-E24 ........ BT-762-CL4 ........ BT-300-D4 ....... BT-300-DC16 ....... BT-300-E4........ BT-300-F1
8-5/8 ........ BT-862-OAC........ BT-500-G2....... BT-600-D5 ....... BT-604-D10........ BT-700-E35 ........ BT-862-CL5 ........ BT-400-D5 ....... BT-400-DC20 ....... BT-300-E4........ BT-300-F1
9-5/8 ........ BT-900-OAC........ BT-500-H2....... BT-600-D5 ....... BT-604-D10........ BT-700-F35 ........ BT-962-CL5 ........ BT-400-D5 ....... BT-400-DC20 ....... BT-300-E4........ BT-300-F1
10-3/4 ........ BT-107-OAC........ BT-500-I2 ........ BT-600-E5 ........ BT-605-E10 ........ BT-700-E40 ........ BT-107-CL5 ........ BT-450-D5 ....... BT-450-DC20 ....... BT-300-E4........ BT-300-F1
11-3/4 ........ BT-117-OAC........ BT-500-I2 ........ BT-600-E5 ........ BT-605-E10 ........ BT-700-F40 ........ BT-117-CL5 ........ BT-450-D5 ....... BT-450-DC20 ....... BT-300-E4........ BT-300-F1
13-3/8 ........ BT-133-OAC........ BT-500-J2 ........ BT-600-F5 ........ BT-606-F10 ........ BT-700-F50 ........ BT-133-CL5 ........ BT-500-D5 ....... BT-500-DC20 ....... BT-400-E4........ BT-400-F1
16 .............. BT-160-OAC........ BT-500-K2....... BT-600-F5 ........ BT-606-F10 ........ BT-700-F50 ........ BT-160-CL5 ........ BT-500-D5 ....... BT-500-DC20 ....... BT-400-E4........ BT-400-F1
20-3/8 ........ BT-200-OAC........ BT-500-L2 ....... BT-600-G6 ....... BT-607-G12........ BT-700-F102 ...... BT-200-CL6 ........ BT-600-D6 ....... BT-600-DC24 ....... BT-500-E6........ BT-500-F1

Section C – Revision: A, 05/11/2011 Page 11 of 20

 Bilco Tools Inc.
Technical Reference Manual
Tolerance Chart for Blade Slots and Blades
TM
Tough Boy Combination Tool
(All dimensions in Inches)
Blade Slot Blade
Dimensions Dimensions
Blade Slot Width – (A) Blade Width – (B) Blade Foot Width – (C)
Tool Body Range Max. Min. Discard Max. Min. Discard Max. Min. Discard
4 1/2 – 5 .655 .645 .670 .630 .620 .600 .740 .730 .700
5 1/2 .655 .645 .670 .630 .620 .600 .755 .745 .705
6 5/8 – 7 – 7 5/8 .800 .790 .815 .760 .750 .745 .880 .870 .845
8 5/8 – 9 5/8 .800 .790 .815 .760 .750 .745 .905 .895 .850
10 3/4 – 11 3/4 – 13 3/8 .925 .915 .935 .885 .875 .860 1.000 .990 .960
13 3/8 – 16 1.050 1.040 1.070 1.000 .990 9.75 1.135 1.125 1.100
20 1.550 1.540 1.625 1.510 1.500 1.485 1.760 1.750 1.675
* Wear Height on Blade is determined by Wear Indicator Hole.

Blade Slot Width – (A) Blade Width – (B)

Max. – Min. Max. – Min.
Discard Discard
Wear Indicator
Hole

Minimum New Blade

Blade Height
Height

Max. – Min.
Discard

Blade Foot Width – (C)

Section C – Revision: A, 05/11/2011 Page 12 of 20

 Bilco Tools Inc.
Technical Reference Manual
Spec. Sheet
TM
Tough Boy Combination Tool

Serial No.: Casing

Model No.: Size/Weight:
Connections, Body, Retainer Cap, and Blades passed M.P.I. prior to assembly
Pin Thread Connection
Measured Pin OD
Measured Tool Minimum ID
Measured Retainer Cap OD
Casing Drift ID
Measured Brush Extension
Brush Element Length
Measured Blade Extension
Measured Blade Retraction
Box Thread Connection
Measured Box OD
Measured Body OD
Tool Body Drifted /Drift Size
Box and Pin Thread Protectors Installed
Serial Numbers Easily Read
Tool Orientation (Pin up or Pin down)
Tool Prepared as per Technical Reference Manual and Correct Parts List
Comments/Additional Information:

Completed By: (sign) Date:

Accepted By: (sign) Date:

Section C – Revision: A, 05/11/2011 Page 13 of 20

 Check In Sheet

Job/Ticket Number:

Customer:

Date Tools Returned

Date Tools Checked In

Check In By

All Tools Returned No Damages

Some Tools Not Returned or Damaged (Describe Below)

(Note Serial # of Unit and/or Part #)

Repairs Completed: Date

Completed By:
Section C – Revision: A, 05/11/2011 Page 14 of 20
 Bilco Tools Inc.
Technical Reference Manual
Redress Kit
Combination Tool
BT-450-OAC-1 4 1/2”
Item Part No. Quantity Description
1 BT-450-OAC-1 1 Tool Body with 3.5 OD and 7/8 ID cut with 2 3/8 reg. Connection
2 BT-450-B 2 Blade Retainer Cap
3 BT-600-A 4 Brush Fixture
4 BT-601-A 4 Brush Element Keeper
5 BT-700-A 24 Brush Element 1.25"
6 BT-450-CL 4 Scraper Blade - Leading
7 BT-100-D 4 Blade Spring (for scrapers with Leaf Springs)
8 BT-100-DC 16 Blade Spring (for scrapers with Coil Springs)
9 BT-100-E 4 Socket-Head Cap Screw
10 BT-100-F 1 Allen Wrench

BT-500-OAC-1 5”
Item Part No. Quantity Description
1 BT-500-OAC-1 1 Tool Body with 3.75 OD and 1.00 ID cut with 2 3/8 reg. Connection
2 BT-500-B 2 Blade Retainer Cap
3 BT-600-A 4 Brush Fixture
4 BT-601-A 4 Brush Element Keeper
5 BT-700-B 24 Brush Element 1.5"
6 BT-500-CL 4 Scraper Blade - Leading
7 BT-100-D 4 Blade Spring (for scrapers with Leaf Springs)
8 BT-100-DC 16 Blade Spring (for scrapers with Coil Springs)
9 BT-100-E 4 Socket Head Cap Screw
10 BT-100-F 1 Allen Wrench

BT-550-OAC-1 5 1/2”
Item Part No. Quantity Description
1 BT-550-OAC-1 1 Tool Body with 4.25 OD and 1.00 ID cut with 2 7/8 reg. Connection
2 BT-550-B 2 Blade Retainer Cap
3 BT-600-B 4 Brush Fixture
4 BT-602-B 4 Brush Element Keeper
5 BT-700-C 32 Brush Element 1.75"
6 BT-550-CL 4 Scraper Blade - Leading
7 BT-200-D 4 Blade Spring (for scrapers with Leaf Springs)
8 BT-200-DC 16 Blade Spring (for scrapers with Coil Springs)
9 BT-200-E 4 Socket Head Cap Screw
10 BT-200-F 1 Allen Wrench

Section C – Revision: A, 05/11/2011 Page 15 of 20

 Bilco Tools Inc.
Technical Reference Manual
Redress Kit
Combination Tool
BT-700-OAC-1 7”
Item Part No. Quantity Description
1 BT-700-OAC-1 1 Tool Body with 5.125 OD and 1.25 ID cut with 3 1/2 reg. Connection
2 BT-700-B 2 Blade Retainer Cap
3 BT-600-C 4 Brush Fixture
4 BT-603-C 4 Brush Element Keeper
5 BT-700-D 24 Brush Element 2.187"
6 BT-700-CL 4 Scraper Blade - Leading
7 BT-300-D 4 Blade Spring (for scrapers with Leaf Springs)
8 BT-300-DC 16 Blade Spring (for scrapers with Coil Springs)
9 BT-300-E 4 Socket Head Cap Screw
10 BT-300-F 1 Allen Wrench

BT-700-OAC-3 7”
Item Part No. Quantity Description
1 BT-700-OAC-3 1 Tool Body with 5.125 OD and 1.25 ID cut with 3 1/2 HT-38 Connection
2 BT-700-B 2 Blade Retainer Cap
3 BT-600-C 4 Brush Fixture
4 BT-603-C 4 Brush Element Keeper
5 BT-700-D 24 Brush Element 2.187"
6 BT-700-CL 4 Scraper Blade - Leading
7 BT-700-D 4 Blade Spring (for scrapers with Leaf Springs)
8 BT-300-DC 16 Blade Spring (for scrapers with Coil Springs)
9 BT-300-E 4 Allen-Head Cap Screw
10 BT-300-F 1 Allen Wrench

BT-700-OAC-6 7”
Item Part No. Quantity Description
1 BT-700-OAC-6 1 Tool Body with 5.125 OD and 1.25 ID cut with 3 1/2 XH Connection
2 BT-700-B 2 Blade Retainer Cap
3 BT-600-C 4 Brush Fixture
4 BT-603-C 4 Brush Element Keeper
5 BT-700-D 24 Brush Element 2.187"
6 BT-700-CL 4 Scraper Blade - Leading
7 BT-300-D 8 Blade Spring (for scrapers with Leaf Springs)
8 BT-300-DC 32 Blade Spring (for scrapers with Coil Springs)
9 BT-300-E 4 Allen-Head Cap Screw
10 BT-300-F 1 Allen Wrench

Section C – Revision: A, 05/11/2011 Page 16 of 20

 Bilco Tools Inc.
Technical Reference Manual
Redress Kit
Combination Tool
BT-762-OAC-1 7 5/8”
Item Part No. Quantity Description
1 BT-762-OCA-1 1 Tool Body with 5.125 OD and 1.25 ID cut with 3 1/2 reg. Connection
2 BT-700-B 2 Blade Retainer Cap
3 BT-600-C 4 Brush Fixture
4 BT-603-C 4 Brush Element Keeper
5 BT-700-E 24 Brush Element 2.50"
6 BT-700-CL 4 Scraper Blade - Leading
7 BT-300-D 4 Blade Spring (for scrapers with Leaf Springs)
8 BT-300-DC 16 Blade Spring (for scrapers with Coil Springs)
9 BT-300-E 4 Allen-Head Cap Screw
10 BT-300-F 1 Allen Wrench

BT-762-OAC-4 7 5/8”
Item Part No. Quantity Description
1 BT-700-OAC-4 1 Tool Body with 5.125 OD and 1.25 ID cut with 3 1/2 HT-40 Connection
2 BT-700-B 2 Blade Retainer Cap
3 BT-600-C 4 Brush Fixture
4 BT-603-C 4 Brush Element Keeper
5 BT-700-E 24 Brush Element 2.50"
6 BT-700-CL 4 Scraper Blade - Leading
7 BT-300-D 4 Blade Spring (for scrapers with Leaf Springs)
8 BT-300-DC 16 Blade Spring (for scrapers with Coil Springs)
9 BT-300-E 4 Allen-Head Cap Screw
10 BT-300-F 1 Allen Wrench

BT-762-OAC-5 7 5/8”
Item Part No. Quantity Description
1 BT-762-OAC-5 1 Tool Body with 5.125 OD and 1.25 ID cut with 3 1/2 XTM-40 Connection
2 BT-700-B 2 Blade Retainer Cap
3 BT-600-C 4 Brush Fixture
4 BT-603-C 4 Brush Element Keeper
5 BT-700-E 24 Brush Element 2.50"
6 BT-700-CL 4 Scraper Blade - Leading
7 BT-300-D 4 Blade Spring (for scrapers with Leaf Springs)
8 BT-300-DC 16 Blade Spring (for scrapers with Coil Springs)
9 BT-300-E 4 Allen-Head Cap Screw
10 BT-300-F 1 Allen Wrench

Section C – Revision: A, 05/11/2011 Page 17 of 20

 Bilco Tools Inc.
Technical Reference Manual
Redress Kit
Combination Brush Tool
BT-862-OAC-1 8 5/8”
Item Part No. Quantity Description
1 BT-862-OAC-1 1 Tool Body with 6.75 OD and 2.00 ID cut with 4 1/2 reg. Connection
2 BT-900-B 2 Blade Retainer Cap
3 BT-600-D 5 Brush Fixture
4 BT-604-D 5 Brush Element Keeper
5 BT-700-E 35 Brush Element 2.50"
6 BT-862-CL 5 Scraper Blade - Leading
7 BT-400-D 5 Blade Spring (for scrapers with Leaf Springs)
8 BT-400-DC 20 Blade Spring (for scrapers with Coil Springs)
9 BT-300-E 4 Allen-Head Cap Screw
10 BT-300-F 1 Allen Wrench

BT-962-OAC-1 9 5/8”
Item Part No. Quantity Description
1 BT-962-OAC-1 1 Tool Body with 6.75 OD and 2.00 ID cut with 4 1/2 reg. Connection
2 BT-900-B 2 Blade Retainer Cap
3 BT-600-D 5 Brush Fixture
4 BT-604-D 5 Brush Element Keeper
5 BT-700-F 35 Brush Element 3.00"
6 BT-962-CL 5 Scraper Blade - Leading
7 BT-400-D 5 Blade Spring (for scrapers with Leaf Springs)
8 BT-400-DC 20 Blade Spring (for scrapers with Coil Springs)
9 BT-300-E 4 Allen-Head Cap Screw
10 BT-300-F 1 Allen Wrench

BT-962-OAC-2A 9 5/8”
Item Part No. Quantity Description
1 BT-962-OAC-2A 1 Tool Body with 6.75 OD and 2.00 ID cut with 3 1/2 IF Connection
2 BT-900-B 2 Blade Retainer Cap
3 BT-600-D 5 Brush Fixture
4 BT-604-D 5 Brush Element Keeper
5 BT-700-F 35 Brush Element 3.00"
6 BT-962-CL 5 Scraper Blade - Leading
7 BT-400-D 5 Blade Spring (for scrapers with Leaf Springs)
8 BT-400-DC 20 Blade Spring (for scrapers with Coil Springs)
9 BT-300-E 4 Allen-Head Cap Screw
10 BT-300-F 1 Allen Wrench

Section C – Revision: A, 05/11/2011 Page 18 of 20

 Bilco Tools Inc.
Technical Reference Manual
Redress Kit
Combination Brush Tool
BT-962-OAC-2B 9 5/8”
Item Part No. Quantity Description
1 BT-962-OAC-2B 1 Tool Body with 6.75 OD and 2.00 ID cut with 4 1/2 IF Connection
2 BT-900-B 2 Blade Retainer Cap
3 BT-600-D 5 Brush Fixture
4 BT-604-D 5 Brush Element Keeper
5 BT-700-F 35 Brush Element 3.00"
6 BT-962-CL 5 Scraper Blade - Leading
7 BT-400-D 5 Blade Spring (for scrapers with Leaf Springs)
8 BT-400-DC 20 Blade Spring (for scrapers with Coil Springs)
9 BT-300-E 4 Allen-Head Cap Screw
10 BT-300-F 1 Allen Wrench

BT-107-OAC-1 10 3/4"
Item Part No. Quantity Description
1 BT-107-OAC-1 1 Tool Body with 8.5 OD and 2.00 ID cut with 4 1/2 reg. Connection
2 BT-110-B 2 Blade Retainer Cap
3 BT-600-E 5 Brush Fixture
4 BT-605-E 5 Brush Element Keeper
5 BT-700-E 40 Brush Element 2.5"
6 BT-107-CL 5 Scraper Blade - Leading
7 BT-450-D 5 Blade Spring (for scrapers with Leaf Springs)
8 BT-450-DC 20 Blade Spring (for scrapers with Coil Springs)
9 BT-300-E 4 Allen-Head Cap Screw
10 BT-300-F 1 Allen Wrench

BT-117-OAC-1 11 3/4"
Item Part No. Quantity Description
1 BT-117-OAC-1 1 Tool Body with 8.5 OD and 2.00 ID cut with 4 1/2 reg. Connection
2 BT-110-B 2 Blade Retainer Cap
3 BT-600-E 5 Brush Fixture
4 BT-605-E 5 Brush Element Keeper
5 BT-700-F 40 Brush Element 3.00"
6 BT-117-CL 5 Scraper Blade - Leading
7 BT-450-D 5 Blade Spring (for scrapers with Leaf Springs)
8 BT-450-DC 20 Blade Spring (for scrapers with Coil Springs)
9 BT-300-E 4 Allen-Head Cap Screw
10 BT-300-F 1 Allen Wrench

Section C – Revision: A, 05/11/2011 Page 19 of 20

 Bilco Tools Inc.
Technical Reference Manual
Redress Kit
Combination Brush Tool
BT-133-OAC-1 13 3/8"
Item Part No. Quantity Description
1 BT-133-OAC-1 1 Tool Body with 10.00 OD and 2.5 ID cut with 6 5/8 reg. Connection
2 BT-160-B 2 Blade Retainer Cap
3 BT-600-F 5 Brush Fixture
4 BT-606-F 5 Brush Element Keeper
5 BT-700-F 50 Brush Element 3.00"
6 BT-133-CL 5 Scraper Blade - Leading
7 BT-500-D 5 Blade Spring (for scrapers with Leaf Springs)
8 BT-500-DC 20 Blade Spring (for scrapers with Coil Springs)
9 BT-400-E 4 Allen-Head Cap Screw
10 BT-400-F 1 Allen Wrench

BT-160-OAC-1 16"
Item Part No. Quantity Description
1 BT-160-OAC-1 1 Tool Body with 10.00 OD and 2.5 ID cut with 6 5/8 reg. Connection
2 BT-160-B 2 Blade Retainer Cap
3 BT-600-F 5 Brush Fixture
4 BT-606-F 5 Brush Element Keeper
5 BT-700-F 50 Brush Element 3.00"
6 BT-160-CL 5 Scraper Blade - Leading
7 BT-500-D 5 Blade Spring (for scrapers with Leaf Springs)
8 BT-500-DC 20 Blade Spring (for scrapers with Coil Springs)
9 BT-400-E 4 Allen-Head Cap Screw
10 BT-400-F 1 Allen Wrench

BT-200-OACC-1 20"
Item Part No. Quantity Description
1 BT-200-OAC-1 1 Tool Body with 14.00 OD and 3.00 ID cut with 6 5/8 reg. Connection
2 BT-200-B 2 Blade Retainer Cap
3 BT-600-G 5 Brush Fixture
4 BT-607-G 6 Brush Element Keeper
5 BT-700-F 102 Brush Element 3.00"
6 BT-200-CL 6 Scraper Blade - Leading
7 BT-600-D 6 Blade Spring (for scrapers with Leaf Springs)
8 BT-600-DC 24 Blade Spring (for scrapers with Coil Springs)
9 BT-500-E 6 Allen-Head Cap Screw
10 BT-500-F 1 Allen Wrench

Section C – Revision: A, 05/11/2011 Page 20 of 20