ken

U R so screwed......

If you have the skill of a dentist and the right tools (right angle
drill, cobalt drills, tap and die set, and some good Karma) just maybe
you can get it out

But, if you're real lucky, with the use of reverse cobalt drills, it
might come out easy

Worse case...breaking off a drill inside the head, breaking off an
"easy-out" (why they call 'em that, I'll never understand) or drilling
off center

ajeeperman

bad news
spray the broken bolt first with a good penetrating oil and let it soak for
hours.
you have to buy an " easy out bit"(reversed threads) and a drill smaller
that the broken bolt.one that fits the easy out bit.
then drill into the bolt with it about 1/4 to 1/2 inch. then use the easy
out that is smaller than the bolt, but slightly larger than the drilled
hole. thread the easy out into the hole(going backwqrds from the normal
direction) and when it grabs the bolt, hopefully it will back the bolt out.
spray the broken bolt first with a good penetrating oil and let it soak for
hours.
good luck.
old john

no one

Can you WELD ???


if so get urself a 3/8 NUT.

now take 7011 rod and weld the nut to the bolt stud un the HEAD VIA the
center of the BOLT.

Wait 45 seconds for the weld to cool, and then use a Wrench on the NUT
to remove the BOLT..

This is the method we use since 1939 at Delduca's welding in BURTON Mi .

elbert

are you talking about the passenger side or driver side...

either way you may end up removing the head to fix this depending
where the bolt actually broke.

One hard lesson I learned... do not put any real force on the small
ease outs... Use the smallest drill bit you can to get a hole
started in the center of the bolt and keep going up in drill bit sizes
until you have a fairly large hole relative to the size of the bolt.
Put your ease out in and tap with a hammer (not real hard) then apply
smmoth even force to the ease out, to see if you can move the bolt.
Be very careful here...this is were it gets to be a real pain in the
ass.

ITs going to be a real bad day if you break an ease out in the bolt.
Because ease outs are harneded metal and they are about impossilbe to
remove once that happens.

Get some good drill bits, and a good set of ease outs. By the way
ease outs are not just left hand drill bits.

The most important task is to get a hole started in the center of the
broken bolt, square with the hole. Of course this is easy to say and
very hard to do. Also it depends on where the bolt broke and even if
you can get in there to drill.

If you have any doubt....take the intake off and most liekely you'll
have to remove the head. If you are able to do so.

Its very easy to make the problem worse.

Ease-outs have saved my #$$ a number of times, but I did break off an
ease out in a bolt one time, where I used to much force on a small
ease out and it broke clean of even in the bolt I was trying to
remove, needless to say I have a few choice words to say.

Expeience goes a long way in this type of work, ask around among your
friends if you have neve done this to see if you can get some help.
---
Elbert Clarke
elbert.clarke@**adelphia.net
remove ** to email

elbert

good idea if you are able to get access to the shoulder of the bolt...

I've done this before too, works good if you have the access.
---
Elbert Clarke
elbert.clarke@**adelphia.net
remove ** to email

the nolalu barn owl <gordie@nolalu.on&#

You will likely have to remove the head to get out the broken bolt.

I have worked as an Industrial Mechanic (Millwright) for 32 years and
can tell you that welding a nut on will get out the broken bolt. The
heat breaks the bolt free especially when it is broken off in cast
iron. Just as soon as the red glow fades you can try the wrench on
the nut and then you will be a believer
It has never failed when I use this method.
--
Regards
Gordie

pete

Hi Will
Mebbe you can drill the hole for the easy out, then heat the bolt/hole if
possible, before trying to back it out gently with the easy out? Don't know
if the heat could hurt anything else....if you concentrated it on the bolt
only....the welding sounds the best, but everybody doesn't have a machine.
Pete

sblackfoot

Just wondering, is this a safe practice with an aluminum head too?

the nolalu barn owl <gordie@nolalu.on&#

Sorry, I can't answer that as my experience only is with steel bolts
broken off inside cast iron.
Someone else may be able to help.
--
Regards
Gordie

the nolalu barn owl <gordie@nolalu.on&#

There is no possible way to weld the nut on with the head still on the
motor unless the motor has been removed. I have looked at mine in the
driveway.
Once the head is in your hands the welding machine is within easy
reach no matter whether you own one, borrow one, rent one or hire a
welder.

The bolts usually break off near flush. Put the nut over the broken
stub and weld down through the hole in the nut joining the stub to the
nut. When the nut cools until the glow is gone try the wrench.
--
Regards
Gordie