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Tool Talk Discussion Forum

Broke off easy-out....Help!

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Roland Jackson

08-22-2005 18:22:13




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There are some days one shouldn"t get out of bed. This morning, before my first cup of coffee, I decided to drill out and remove a broken stud bolt in the engine head of my Dodge Van. I did a great job of drilling the stud in the center, however, when trying to remove it by using an easy out..the easy out snapped off in the hole. Now I have a hardened tool in place of the bolt I was trying to remove. I slotted the exposed end of the easy out in hopes that I could twist it out....no luck. I heated it and tried to turn it out. Anyone have any ideas how I can remove the easy out?

Thanks in advance for your help....

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Vern-MI

08-23-2005 04:57:29




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 Re: Broke off easy-out....Help! in reply to Roland Jackson, 08-22-2005 18:22:13  
I will assume that the broken bolt is 1/2 inch and that the EZ-out is broken flush with the top surface of the block. What kind of welding equipment do you have? See if you can weld a rod to the EZ-out. The use a slide hammer attached to the rod and jerk the EZ-out from the hole.



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jhill

08-22-2005 23:28:20




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 Re: Broke off easy-out....Help! in reply to Roland Jackson, 08-22-2005 18:22:13  
Take it to a machine shop that has an EDM ( Electro Discharge Machining) machine and have it burned out. It will not hurt the threads and isn't too expensive.



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Fred Martin

08-22-2005 20:40:30




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 Re: Broke off easy-out....Help! in reply to Roland Jackson, 08-22-2005 18:22:13  
Roland...you need a drill instructor....go to the nearest marine corp recruiting station and get one! And I guarantee you will never do that again! The rest of the guys have told you the only good ways of repairing this error. It could even get worse if you try shattering it without using safety glasses. You actually should use a suit of armor...that stuff sometimes comes out like a missle. Now, go throw all the rest of those mis-named things away...and all the rest of you guys reading this post! Sorry...theres no magic fairy on this one. Fred OH

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Ludwig

08-23-2005 11:20:38




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 Re: Broke off easy-out....Help! in reply to Fred Martin, 08-22-2005 20:40:30  
I'm with you Fred, I've broken every easy out I've ever tried to use.

If you can get it to start you MIGHT be able to drill it out with a carbide drill bit. More than likely you'll just booger up everything around the easyout though. A very talented person with a torch can burn one out, thats WAY beyond anything I can do but I've seen it done before.



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msb

08-22-2005 20:16:50




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 Re: Broke off easy-out....Help! in reply to Roland Jackson, 08-22-2005 18:22:13  
I would weld a washer to it and then weld a nut to the washer.Try to also weld the bolt to the washer too.Put a wrench on the nut and turn the whole thing out.



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glennster

08-30-2005 18:47:05




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 Re: Broke off easy-out....Help! in reply to msb, 08-22-2005 20:16:50  
go to your local welding supply store and buy a stud removal rod. it is used in a stick welder. you place a nut over the broken stud and then weld thru the center of the nut, puddle the top so it mushrooms. i use a grade 8 nut. the rod has a tensile strength of about 100,000 psi. let it cool a minute or so and then back the nut out. the rods are about 4-6dollars a piece, but they are well worth it. you can get a half dozen uses out of each rod. we use them when the exhaust bolts break off in the cylinder heads, they work good thx

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MarkB_MI

08-22-2005 18:53:57




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 Re: Broke off easy-out....Help! in reply to Roland Jackson, 08-22-2005 18:22:13  
I have had success grinding out a broken easy-out with a carbide burr in a die grinder. I used a burr slightly smaller than the bolt diameter with a rounded tip.



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Larry806

08-22-2005 18:33:57




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 Re: Broke off easy-out....Help! in reply to Roland Jackson, 08-22-2005 18:22:13  
I don't know about it now that you heated it. The best thing I've used is a center punch to break the easy out or tap. Their hardened steel and shatter



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BigMarv1085

08-22-2005 18:48:20




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 Re: Broke off easy-out....Help! in reply to Larry806, 08-22-2005 18:33:57  
Try using a dremel tool to grind out the center and then see if you can shatter the rest with a small punch or chisel. The heat will definetly make it harder to get out. Good luck.



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