Broken primary mounting bolt
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Novice
Joined: Jun 2021
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From: Pittsburgh
Broken primary mounting bolt
Hello, in sorry if this is discussed elsewhere. I'm not good at navigating this site. When removing one of the 5 primary mounting bolts. One snapped. Leaving me with a 1/2" nub. It seems really tight. Even so tight my vice grips applied with pliers won't stop from slipping. Was thinking of welding a nut onto it. Just a little nervous. I don't want to make it worse. Any suggestions on a extraction procedure?
2007 Softail deluxe
2007 Softail deluxe
Seasoned HDF Member
Joined: Sep 2008
Posts: 14,255
Likes: 11,384
From: San Diego, CA
Hello, in sorry if this is discussed elsewhere. I'm not good at navigating this site. When removing one of the 5 primary mounting bolts. One snapped. Leaving me with a 1/2" nub. It seems really tight. Even so tight my vice grips applied with pliers won't stop from slipping. Was thinking of welding a nut onto it. Just a little nervous. I don't want to make it worse. Any suggestions on a extraction procedure?
2007 Softail deluxe
2007 Softail deluxe
Are you talking about the 5 inner primary cover screws (#786A 5/16-18 x 2-1/4 hex head, grade 5)..?
I suspect welding a nut on the end is the best way with what you have... the heat may help loosen it up too.....
I'm not a welder, so I have no cautions or advice to give in this specific application, but I have read about many a broken bolt being removed successfully that way...
Grand HDF Member
Joined: Jul 2012
Posts: 3,974
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From: Omaha
Hello, in sorry if this is discussed elsewhere. I'm not good at navigating this site. When removing one of the 5 primary mounting bolts. One snapped. Leaving me with a 1/2" nub. It seems really tight. Even so tight my vice grips applied with pliers won't stop from slipping. Was thinking of welding a nut onto it. Just a little nervous. I don't want to make it worse. Any suggestions on a extraction procedure?
2007 Softail deluxe
2007 Softail deluxe
You’ll likely get more ideas there.
As for me I think I would spray the screw down with PB Blaster or WD-40 and let it soak in overnight.
Then I’d apply direct heat to the screw and try either a reverse drill bit or an easy-out bit.
Harbor Freight sells cheap reverse bits and Lowes sells easy-out kits and individual bits.
With the reverse drill bit method you would drill a small hole into the center of the screw using a regular drill bit.
Note that the key is start slow with a small bit and work you’re way bigger if needed.
Don’t put a lot of pressure on the bit, let it do the work.
You don’t want to break a bit off in the screw as that will make things worst.
Once you’ve drilled a small hole using a regular bit, apply direct heat and take a reverse bit and start slowly drilling into the screw.
If you’re lucky the reverse bit will grab hold of the screw and unscrew it.
If you not lucky the bit will just stop, but as mentioned go slow as you don’t want to break off the bit.
If the reverse bit doesn’t work then get you an easy-out kit.
With an easy-out bit the principle is the same as using a reverse bit, with the exception the easy-out bits are designed to dig into the screw/bolt.
I would still apply direct heat to the screw.
If the reverse bit or easy-out bits down get the screw out you might just have to drill it out then using a tap and die make new threads for an oversized screw.
If you’re uncomfortable doing all this then start calling on local machine shops and see if you can find one that is willing to get the screw out for you.
In my 20+ years working on military aircraft I come to determine that there is no stuck screw that a good machinist can’t get out.
Good luck.
Last edited by Bluraven; Sep 16, 2022 at 07:22 AM.
Stellar HDF Member
Joined: Apr 2016
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From: Masshole
If there is a 1/2" sticking out there is no need for drilling or ez-outs..... yet! Heat is your friend here, few heating/cooling cycles then your vice grips. Try that a few times but stop immeadiatly if the vice grips continue to slip as you want to keep as much meat on the remaining screw as possible. If that fails, go to welding on a nut, you are certainly not going to make it worse!
Stellar HDF Member
Joined: Sep 2021
Posts: 2,125
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From: Black Hills of SD
The above method is what I would do. I would also use a penetrating oil overnight before doing anything. Let it do its thing, and it will penetrate and work. Use an actual penetrating oil like PB or similar, Break-free or Free All.
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Novice
Joined: Jun 2021
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From: Pittsburgh
Thanks for the good advice. In 30 years of working on my own cars and bikes, I've never given them to anyone to finnish.. I will try a Bosch Extractor set. Hope I don't have to trailer the bike to a machine shop....
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