Whoa-- take a step back now and think about this.

You have a flush bolt with a drill broken inside the hole. Now you have to drill into part of the broken drill bit which is harder than the material of the broken bolt.

Based on experience I think that it is now unlikely you will be able to drill the bolt on center (for the extractor) as if you got close to center of the broken bit, the new harder bit will probably bounce off the center every time it touches the broken off bit.

Further you have to position the extractor very close to the center of the broken bolt because if you touch the threads of the bolt hole with the extractor it will bind against the threads and you will be no further than you are now.

My suggestion is to take it to a quality welding fabrication shop who will center a nut over the broken bolt and run a bit of tig bead to the flush head and the inside of the nut.
They will then be able to back the bolt out with a wrench on the nut. The heat will also shrink the broken bolt and I assure you it will turn out easily.

Make sure you disconnect the battery before welding takes place and you will have no electrical issues, and shield any areas you don't want any heat on with water wet rags.

I removed a broken footboard bolt with an extractor broken off in it with a stick welder (SMAW) and if it can be done with that, the Tig process will be even easier and cleaner to perform.
When I did mine I wire brushed the area around the mount tab and hit it with rattle can black after it cooled down.

If you speak with a good fab shop you will know if they can successfully perform the above process. I reckon an hours labour charge (or less) will see it done.

Whatever you decide to do I hope it works for you-- I found further drilling to be a waste of time once I broke the extractor off in it.

 

Sorry cass-- I didn't see this repair post before I posted the suggestion more or less for the same fix.

Happy to hear it's fixed.

Cheers,
V2Evo96

 

I did mine and the right side rear did the same as your but at that time I only had a manual set of allen wrenches and had yet went to the auto parts and got the one that fit my ratchet. I just backed it out ran it in and did that 4 or five times and it went in. If I had or went and gotten the adaptor first I would of busted mine off I know I would of. Friend of mine calls me Magilla Gurilla when it comes to breaking off bolts.......

 

I have the extensions on my bike, and this post makes me feel good! I had no problems installing mine (except getting the originals off). Good post Tom.

chuck

 

It may expand the bracket, but heat does not shrink the bolt.

 

Yes-- you are correct-- I reversed the expansion/contraction rule. Thanks for pointing that out.

Cheers, V2

 

Well put on the floorboard extenders on my 14 Limited..all went ok until the rear right side bolt..cant get it to tighten, seems like its hitting the bottom of hole. Dont know if its cross threaded ..sure hope not, i cleaned hole with wire brush to see if any loctite was in the way, cant even get the original bolt to go all the way in..should i try a thread chaser?

 

Before you put another bolt, tap or chaser in that hole check the depth to be sure that it is at least ( preferably deeper ) as deep the bolt is long. A simple wire ( coat hanger ) or the depth end of a vernier caliper will help!