Re: Re: How to remove a broken bolt (Please help)
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Posted by E.Allison on September 29, 1998 at 10:51:17:
In Reply to: Re: How to remove a broken bolt (Please help) posted by Gerald on September 29, 1998 at 08:16:14:
: : I have an aluminum steering gear housing with a bolt broken off in it. The bolt is about a 3/8" x 1 1/2" bolt. I've already drilled the center of the bolt out with about 7/64" drill bit the entire length of the bolt. Only one end of the bolt is visible. I tried to use an easy out but it wasn't budging and I didn't want to break the easy out off in the bolt. : : Can I heat aluminum? Can I try to weld a new bolt head to the bolt? Should I just drill it out completely and use a heli-coil? : : Please comment. : I don't where to get it, but nitric acid will eat the steel bolt and not touch the aluminum. It will also eat flesh, lungs, clothes and the like. : Otherwise penetrations of penetrating oils such as kerosene, wd-40, liquid wrench, and pierce (the best of the lot that I've had succes with, kerosene and WD-40 seem equally ineffective) are more effective if the stuck parts are violently jarred to open up a crack in the corrosion for their entry. But don't peen over the ends of the bolt to make a rivet! : Have you considered retapping the hole in the steel, say for a 5/16" bolt and then put a sleeve around the bolt in the other piece? The heat of drilling and tapping may loosen the stuck bolt or just prove its really stuck. : You can heat aluminum but not violently, it melts before it glows. Aluminum does expand faster than steel so heat is one way to loosen up a stuck bolt. Better with a hot air gun than acetylene or even propane. Have you actuallt tried the nitric acid? It sounds like it might work. I hate to see steel bolts in aluminum, I've spent hours with similar problems, I guess stainless bolts or anti-seize compond cost too much for the people building this stuff. EEA
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