removing broken bolts

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Aug 30, 2008 | 01:56 PM

72 Ironhead XLH

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Road Captain

Joined: Jul 2005

Posts: 578

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From: New Jersey

removing broken bolts

Try drilling a clearance hole thru the broken part to relieve stress,
tap in a "Torx" socket or section of a "allen wrench" to remove the broken part.
A straight fluted tool does not produce the twisting stress that can break a "easy-out"

Aug 31, 2008 | 10:59 AM

Lakerat

Road Warrior

Joined: Sep 2006

Posts: 1,826

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From: Cookson, Ok

Good point. I take it a step farther and use left handed drills, most of the time the piece of broken bolt comes out with that. Take what ever precautions necessary to ensure drilling dead center of the bolt. I use a center punch ground down to a slim,sharp point to increase visibility. Once the center is well established, then use a normal center punch. I use a center drill to start the hole and use the smallest possible L.H. drill for the first attempt. Again, be sure the hole is in the center of the bolt. If the hole ever gets into the thread, you're screwed. If the bolt didn't come out, then I step up to the next size L.H. drill and go back in. The snatching of the slightly larger drill will sometimes break it loose. Keep stepping up on drill sizes til you get close to the thread. I have never tried the Torx bit trick but sounds like a good idea. That's something I learned after 25 years as a repair machinist, there is always a better idea out there. I use straight EZ outs, never the twisted. If the bolt is really stuck the straight ones will just spin in the hole instead of just getting tighter. I use a small crescent wrench to turn the tool, lightly tapping on it with a small ball peen to shock it and keep it seated in the hole
A good industrial supply house will have the left hand drills and straight EZ outs. Patience is a real virtue when removing broken bolts, you must take your time and be careful because you only get one shot.

Last edited by Lakerat; Aug 31, 2008 at 11:05 AM.