broken flush AC stud mount bolt - worth it to get out?
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Cruiser
Joined: Feb 2015
Posts: 135
Likes: 11
From: Lincoln, NE
broken flush AC stud mount bolt - worth it to get out?
I was installing my Screamin eagle air cleaner kit on my 2012 fatboy lo and I'll just be honest. It was 3am and I wasn't thinking right. I did not think about why I would want to be applying 60 foot pounds of torque to a such a small bolt (should be inch not foot..) and one of them snapped....Well it's on there and the gasket is sealed good and tight. Functionally everything should be just fine.
So my question is it worth it to get out?? I am scared of using an easy out and having it break and creating a bigger problem. Also scared of the drill slipping and marring up my throttle body. Not sure if I drilled it out and retapped if a new HD stud will still fit. (I already bought another one in case) My OCD really wants to get it out and have this installed right.
Heres the second part. I'm pretty sure I over torqued the crap out of the breather bolts too going into the cylinder head. Not sure If I need to worry about that and take em out and retorque them properly. I bought new gaskets to do so in case. Wouldn't be able to get to them though unless I can get the stud bolt out I mentioned above.
Thanks for any advice or help!
So my question is it worth it to get out?? I am scared of using an easy out and having it break and creating a bigger problem. Also scared of the drill slipping and marring up my throttle body. Not sure if I drilled it out and retapped if a new HD stud will still fit. (I already bought another one in case) My OCD really wants to get it out and have this installed right.
Heres the second part. I'm pretty sure I over torqued the crap out of the breather bolts too going into the cylinder head. Not sure If I need to worry about that and take em out and retorque them properly. I bought new gaskets to do so in case. Wouldn't be able to get to them though unless I can get the stud bolt out I mentioned above.
Thanks for any advice or help!
Last edited by tkuligowski; Feb 18, 2017 at 11:35 AM.
Seasoned HDF Member
Joined: May 2012
Posts: 32,934
Likes: 36,032
From: Carlsbad, CA
Well that sux. We've all done stupid things. And I still need to remove the head of a broken round head allen tool from a primary cover screw.
Anyhow...my OCD would drive me nuts by not fixing that. Plus there is a reason for all the bolts, so I'd fix it. Regardless of how good your drill bits are, buy a new good quality one(s) for this job. Stuff a clean rag into the throttle body, and then put duct tape over it. Drill a pilot hole first with a much smaller bit, then the proper size. Drill slowly and carefully. After you get it out, you might want to run a thread cleaning tool,through it...not a tap. Then vacuum the area well, before removing the tape and stuffing from the throttle body.
Good luck...
Anyhow...my OCD would drive me nuts by not fixing that. Plus there is a reason for all the bolts, so I'd fix it. Regardless of how good your drill bits are, buy a new good quality one(s) for this job. Stuff a clean rag into the throttle body, and then put duct tape over it. Drill a pilot hole first with a much smaller bit, then the proper size. Drill slowly and carefully. After you get it out, you might want to run a thread cleaning tool,through it...not a tap. Then vacuum the area well, before removing the tape and stuffing from the throttle body.
Good luck...
Sponsor
Joined: Jul 2015
Posts: 8,538
Likes: 1,646
From: SF Bay area
Start out by center punching a small dent right in the center of the bolt. then get some of these... http://www.harborfreight.com/center-...-pc-60381.html from harbor Freight or elsewhere. They're called center drills, and won't walk off center like a regular drill bit. You just use them to make a shallow start hole in the bolt, then follow with a regular drill bit. An easy out from there & you're home free.
Good luck
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Good luck
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Thread Starter
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Cruiser
Joined: Feb 2015
Posts: 135
Likes: 11
From: Lincoln, NE
Thanks for the helpful hints guys. I was able to get it center drilled. I bought a Ez Out kit but the drill bits in the kit sucked. I got about a 1/4 inch drilled but couldn't get the ez out to catch. I have a crap ton of torxs bits around so I hammered that in the small hole I was able to drill and was able to unscrew it right out..phew. Glad to be done with that mess!
Club Member
Joined: Jul 2014
Posts: 11,471
Likes: 3,572
From: Idaho
First of all, boy do I understand why you couldn't leave it...I'm the same way. Drives some people crazy. I tell them I'm easy to understand: "I just want everything to be perfect." 
Second, what a great idea! Sacrifice a torx bit, hammer the right size into the pilot hole, and back it out. I'm saving that one!
Second, what a great idea! Sacrifice a torx bit, hammer the right size into the pilot hole, and back it out. I'm saving that one!
Road Captain
Joined: Nov 2016
Posts: 628
Likes: 112
From: Sparks Nevada
Left hand drill bits
Have complete set these have been a life saver bit usually takes broken bolt out while drilling and forgo ez out. Wild Bill
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Road Master
Joined: Aug 2012
Posts: 1,008
Likes: 229
From: Saskatchewan
Every shop should have a set of left hand drill bits. I have yet to find a broken bolt that has not backed out before I got all the way through it. I also keep a set of "spiral fluted" style easy outs just in case. They seem to work a little better than a straight fluted easy out.
I am not in the habit of breaking bolts, but I have had to deal with many after years of operating heavy equipment.
I am not in the habit of breaking bolts, but I have had to deal with many after years of operating heavy equipment.
Last edited by Sparkee...; Feb 23, 2017 at 01:58 PM. Reason: spelun
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