Re: Re: How to remove a broken bolt (Please help)
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Posted by E.Allison on September 30, 1998 at 07:42:18:
In Reply to: Re: How to remove a broken bolt (Please help) posted by Zane(WA) on September 29, 1998 at 11:16:27:
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: : 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. : Two more things to consider -- The most common "Easy-Out" are the ones that screw in as they are turned. A nice idea I suppose, but I've thrown them out or have given them to someone I don't like very well. As they screw in they also exsert pressure on the side wall of the broken bolt, most of the time causing as much damage than just drilling the bolt. I've been using the square shank easy-outs with much better success for leaving the hole threads intact. The other tool I've used with pretty good results are a set of left-handed drill bits. Since the bit is turning in the direction you want the bolt move it will often times come out without any additional work.The bits are hard to find sometimes, but well worth it. Excellent advice. I need to find some people I don't like to give my screw type "easyouts" to. I have found them to be less than useless. Withe the bolt seized so tight that it broke off, what chance does an easyout of less diameter have? When the break is in steel I resort to my welder with good results. I'm tempted to try the arc welder on the aluminum next time. Actually, the anodizing (mentioned below) sounds like an excellent idea for those extra tough ones. Drill out till you are near the threads and the eat the steel away with the anodizing process! I can't say I'm looking foward to the next time this happens to try it, but it does have my curiosity stirred.
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