So I just changed the fuel filter on a crossbones and while tightning down one of the bolts, the damn bolt head snaps clean off, hadn't even torqued it down yet. It was a new bolt.

What are my options? I thought about just leaving it and worry about it next time. The diameter is to narrow to use a bolt extractor, to deep to weld anything on it, at least I think it is.

Worst case scenario I'll get a new (bran used) tank and fuel system next time I have to get into the gas tank so its not so bad I guess.

 

Try a left hand drill bit. Get a good mark with a center punch and use a small bit and a lot of patience.

 

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You really wanna get that off and use a good bolt. If that canopy isn't tightened down evenly, you could get gas leaking out. Left hand drill would be the best idea, or take the canopy off again and see if theres enough bolt left to grab. Might run a tap through the hole once it's clear to make sure the threads aren't damaged.

 

Use this. Home Depot and Lowes sells a similar product. Speed Outs or something like that.

https://www.grainger.com/product/1U2...170512194647:s

Here's the Home Depot version.

http://www.homedepot.com/p/Ontel-Spe...Q&gclsrc=aw.ds

 

Did you remove the canopy plate yet? If not, I would think there may be enough of the screw remaining to get a vice-grip on and back it out.

 

If this is your first attempt you may want to practice this once on some leftover junk.

 

I just swapped tanks. I would leave it till next time. Doubt very much it will leak, (maybe if the screw works its way out) - which would be welcome. Before you pull the rest of the screws, order replacements.

 

Pull the top off, screw should not be bottomed out, should come right out with your fingers.

 

If this is top of tank, I wouldn't worry about it until I see gas there.