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Tool Talk Discussion Forum

Broken Bolt

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Stevenn

10-10-2004 14:22:17




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I broke a bolt off in the water neck where the thermostat goes. Well now I drilled it out "somewhat" but not deep enough to tap yet. Can that be drilled and tapped? I think now that I"m drilling it with a 5/16" bit I would have to tap it with a 3/8" tap? I may have to have it heliarced??? Don"t know what to do now??? HELP! Thanks Steve.




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JohnnyJ

10-10-2004 20:05:22




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 Re: Broken Bolt in reply to Stevenn, 10-10-2004 14:22:17  
The next time you break off a bolt in a cast-iron housing, try welding a nut to the bolt. I use E6011. If the bolt is deeper than flush, you may have to keep dabbing one little spot on top of the other until you get it flush or slightly above. (Try to weld only on the bolt, but the 6011 will ONLY stick to the bolt, not the casting, so you don't have to worry too much about welding the bolt to the casting). Then weld the inside of a larger nut to the broken stud. Take a spray bottle with water, and spray ONLY the nut until cool. The heat breaks the rust, and you will be able to simply unscrew the broken bolt! (you may have to turn both ways a little at a time until the rust is totally broken loose) This works like a charm, (has never failed once for me - I have a welding shop, and have had to extract many broken studs, but occasionally I have had to repeat the process before getting it out as the nut MAY break off) and is a heck of a lot easier than drilling and tapping!

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JMS/MN

10-10-2004 18:57:59




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 Re: Broken Bolt in reply to Stevenn, 10-10-2004 14:22:17  
Your drill and tap sizes are correct. You may need to use a bottom tap after starting the rethread with a standard tap. If you have a broken standard tap, just grind the broken end square to the shank, and you have a bottom tap. That means the bottom-most thread is full size, and can cut to the bottom of the hole, but you need to start the thread with a tapered standard tap.



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lucas boy

10-10-2004 18:54:16




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 Re: Broken Bolt in reply to Stevenn, 10-10-2004 14:22:17  

the 5/16 dril should work for the 3/8 tap. driilling an 1.8 hole first will make it easier to drill. get it centered or it may not thread well. lucas



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CNKS

10-10-2004 16:46:35




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 Re: Broken Bolt in reply to Stevenn, 10-10-2004 14:22:17  
If you are able to drill it out without harming the threads, or if only minor damage, use a tap that matches the bolt you drilled out and clean the threads. Or you could go up one size and use the appropriate tap. Taps are marked for the proper drill size. Or, as you said, use a helicoil or something similar. The only important thing is that you are able to get the bolt tight and prevent leaks.

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