broken bolts in aluminum

ericlb · Jun 22, 2016

im working on a cylinder head off a utv, it belongs to a friend of mine otherwise i wouldnt touch one of the things , dont know much about them, and since it doesnt say "harley" on it im not much interested in learning lol, but besides a bent valve it has 2 bolts a little smaller than 1/4 inch broken off in the head, below the surface, im wanting to get them out as they hold the exhaust manifold on and it probably needs them, these things have obviously been broke off for awhile and im planing on trying to drill a pilot hole thru the bolts,and try a eze out first, im plenty bothered though first this engine is water cooled and i dont know where the passages are relative to where the bolt is in the head , then the bolts are so small im afraid a small eze out will just break off then i really have problems, also im leary of heating the aluminum with a torch to help the bolts come free, the brand is hisun, which is an odd ball over here although my son who is stationed in japan with the navy says the brand is everywhere over there, one of the most popular ones , any advise will be appreciated for this

Mike M · Jun 22, 2016

DO NOT use an easy out !!!!!!!!!

Find a place with a milling machine and have them drill them out. You will not believe how much easier it is to drill them out and feel what's going on in a mill.

Donald Lehman · Jun 22, 2016

Those are probably 6mm. bolts. I agree with Mike. The chances of messing up on bolts that small is astronomical. Let an honest to goodness machinist tackle this one.

Steve@Advance · Jun 22, 2016

Sense the head is coming off to replace the valve, chances are the seats need to be cut, guides checked, good idea to surface any aluminum head...

Take it to a machine shop that does head work, have it gone through, and while it's there let them get the bolts out.

ditchwitch · Jun 22, 2016

If i were to challenge it i would drill my pilot hole first then spray it with PB blaster or wd40. Let it set a while. Then heat it up around the broke bolt spray it again let it set a few then try to back it out. But that would be me if i had to attempt the job

Dave Sherburne, NY · Jun 22, 2016

Ask your son to get you a new head and send it to you.

Oregon Tractor Jack · Jun 22, 2016

First choice would be a machinist and a mill. I have in the distant past fabricated a drill guide for a similar problem. I used some scrap steel and with careful measurement drilled holes that matched what ever I could bolt too on the work piece. The first part of the drill guide was 1/4" plate. For the actual drill guide I used a piece of 3/4" hot rolled welded to the base plate. It worked pretty well. This is a one shot tool. With out a hardened drill bushing the drill bit will eat the mild steel.

OTJ

37chief · Jun 22, 2016

If you contact salvage yards, you may find a used head. Like someone else said: a mill is the best thing to use. Stan

RyanTN · Jun 22, 2016

I recently saw a very interesting video on YouTube where a guy uses alum powder (used for pickles) to chemically dissolve steel bolts stuck in aluminum. I would post a link, but both videos use quite a bit of profanity for adjectives. If interested, search "remove broken bolt aluminum alum" in YouTube. Hope that helps.

RusselAZ · Jun 22, 2016

Tools needed to get broken bolts out of aluminum parts. Auto darkening welding helmet; A wire feed welder; vise grips(small).

The auto darkening helmet so you can position the wire to hit the steel bolt, then just spit a ball of weld on the bolt. The weld well not stick to or harm the aluminum. Keep spitting weld at the bolt till you have enough built up to get ahold of it with the vise grips and turn it out. likely a 6mm bolt.

wi11y · Jun 22, 2016

if you can find a machine shop with a EDM, it would probably only cost you about $15 to get it removed.

EDM = Electron Displacement Machining. Wonderful machine, they have been around since world war two. Still in use by many machine shops.

broken bolts in aluminum

ericlb

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Mike M

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Donald Lehman

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Steve@Advance

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ditchwitch

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Dave Sherburne, NY

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Oregon Tractor Jack

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37chief

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RyanTN

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RusselAZ

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wi11y

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