Author Topic: Broken bolt  (Read 1524 times)

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Offline Rocco Zugellos

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Broken bolt
« on: November 30, 2008, 12:21:00 pm »
I have sheared off one of the 6mm bolts that hold the thermostst manifold on to the backside/ carb side of the engine. Its proving impossible to drill out, as in my first attempt I broke the bolt extractor off in the hole. Any suggestions would be appreciated.  

Offline Pat and Sher in MA

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Broken bolt
« Reply #1 on: November 30, 2008, 01:36:00 pm »
Have you tried lots of penetrating oil?  How about a little heat to help break it free?  You may also want to try using a left hand drill bit  which may back it out during the drilling process.  Pat & Sher in Ma.  04 Dark Angel  87 Ninja 600rx  84 Guzzi T-5
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Offline Zorlac

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Broken bolt
« Reply #2 on: November 30, 2008, 01:39:00 pm »
Soak it for a day or two with PB Blaster and then go after it with one of these?  http://www.irwin.com/irwin/consumer/jhtml/detail.jhtml;jsessionid=NIAUGP0YCGGGSCQIUBSCF3QKBCQHQJCK?prodId=IrwinProd100128    You may end up having to re-tap the hole.  
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Offline Colin

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Broken bolt
« Reply #3 on: November 30, 2008, 04:45:00 pm »
A common error is to use a bolt extractor that's a bit too small.    If you have managed to remove the broken extractor then make the whole bigger if you can do so without catching the threads and use the next size up. PB blaster and heat will help.    Good luck!    CP    Colin Prior  Cogmos Committee Chairman  Lake Forest Park WA  COG#7767    
« Last Edit: November 30, 2008, 09:04:00 pm by colinp386 »
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Offline Rocco Zugellos

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Broken bolt
« Reply #4 on: December 01, 2008, 12:22:00 pm »
Thanks for the replies. Unfortunately I've tried them all. Using too small an extractor was part of the problem and at this point I know the threads will have to be re-tapped - if I can get enough metal out, so I'm trying a tungsten cutting bit to hopefully open up the hole enough to try a larger extractor or remove all the metal. Ahhh, just the latest DPO problem in my new (to me) baby, gotta pay those C10 dues to be a real Connie rider.  

Offline Brett0769

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Broken bolt
« Reply #5 on: December 01, 2008, 04:23:00 pm »
I got to enjoy this particular issue on a thermostat on my ex's '83 Camaro. That was a really fun 6 hours or so of cursing the machining gods, but eventually drilled it out and retapped it. Had some expert help at the time too, but occasionally there's just no substitute for elbow grease.  
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Offline 2linby

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Broken bolt
« Reply #6 on: December 01, 2008, 09:50:00 pm »
If the manifold does not leak then leave the darn thing alone!  AKA "2linby" That's 2-lin-by folks!  Northwest Area Director  COG #5539  AMA #927779  IBA #15034  TEAM OREGON MC Instructor    http://community.webshots.com/user/2linby  http://tinyurl.com/njas8 (IBA BunBurner Gold Trip)  http://tinyurl.com/lwelx (Alaska trip)
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Offline Rocco Zugellos

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Broken bolt
« Reply #7 on: December 02, 2008, 11:48:00 am »
Thanks again, I wasn't sure if it would leak or not and didn't want to get everything back together to find out...However to anyone in a similar situation the Dremel tungsten cutting bit (used in a regular drill) removed anything in its way. Retapped now and ready to go...  

Offline Rev Ryder

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Broken bolt
« Reply #8 on: December 03, 2008, 12:45:00 am »
I see you got it fixed... I would have suggested trying to mig weld a nut on the end of the broken bolt and turn it out while still hot.  It works mighty well most of the time.  Since the head is alluminum, the weld wouldn't stick to it only to the stud left behind.  
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