Broken easyout removal

[SPOONMAN1]

Broke off flush. The bits I have won't cut it, any suggestions?

 

[Bob_VT]

Re: Broken easyout removal

depending on what it is in and the position..... people will sometimes lay a nut atop of the broken bolt and weld up the center of the nut to the broken bolt.

It's not a good thing when it breaks. What is the bolt or stud in? Is it stuck in steel, cast or aluminum?

 

[Bubbles Up]

Re: Broken easyout removal

Try heating the area around the broken easy out and cool the easy out with super cold 134(a), after u have used a cobalt or titanium bit to drill thru the center it will relieve the tension.BTW this is not an easy or quick job.When you are the hunt for the bit look for a left handed bit the LH twist will help spin easy out and bolt/stud out.If you have to resort to a RH bit it will loosen the easy out then drill out bolt and re tap.
Post a pic that may help.

 

[SPOONMAN1]

Re: Broken easyout removal

It is in an aluminum head, 5/16 bolt, welded the nut (bolt still broke below flush) pryor to drilling and using easy out, it broke off flush or a little below, I guess I'll look for a carbide drill bit (LH). thanks

 

[v1_0]

Re: Broken easyout removal

Ooooo... bad times. This happened to me once.

I'm guessing you have found that a regular drill (from LowDepo) will pretty much just make a shiny spot on the broken easyout. Can't drill a hole for another easy out... (plus you would have to have a easyout that twists in the opposite direction than the first easyout).

What worked for me was a carbide drill bit.

In the scheme of things, the easyout is (or should be) made to be harder than anything it needs to remove. Now, this also makes it harder than the common drill bits (even with the exotic coatings) - which means they aren't hard enough to 'bite' on the easy out. The carbide is harder than the easy out, so will cut it. (Seems like a diamond grit bit would also do the job).

Just one note about carbide - it is harder, but also more brittle. It will chip, can break, etc. so be careful and go slow.

 

[Bubbles Up]

Re: Broken easyout removal

Once you have done the slow process of drilling the easy out with the left hand bit (remember drill in reverse).
The best tip I can give you is use anti seize compound! steel and aluminum will create galvanic corrosion.I use anti seize on every bolt that I can ,it will save this aggravation.

 

[bruceb58]

Re: Broken easyout removal

Once you have done the slow process of drilling the easy out with the left hand bit (remember drill in reverse).
The best tip I can give you is use anti seize compound! steel and aluminum will create galvanic corrosion.I use anti seize on every bolt that I can ,it will save this aggravation.

Why would you use a left hand bit to drill out the easyout? You want to use a right hand bit because that would be opposite of the direction that the easyout went in with.

 

[jonesg]

Re: Broken easyout removal

If all else fails , a spark discharge machine or EDM will dissolve it and leave the alum block intact, it takes a few hrs, sometimes overnite.
A machine shop will do it.

 

[Tubingluvr]

Re: Broken easyout removal

I have been able to get them out with a dremel and screwdriver depending on how good of a bite the easy out has on the bolt.
Just use a cut-off disk in the dremel or roto zip to cut a straight groove in the easy out and back it out with a screwdriver.

 

[SPOONMAN1]

Re: Broken easyout removal

Bruce, it really pi##'s me off not to see the obvious. Good call. I got a carbide tipped die drill from work, tool man says it is made for this application. Will give it a shot tonight, Thanks by the way this is on a 30 yr old pos lawnmower.

 

[4JawChuck]

Re: Broken easyout removal

A concrete drill will make easy work of this project, low rpm and lots of pressure does the trick. Best part about this trick is you can get concrete drills anywhere and it will cut anything including full hard tool steel, be prepared to push hard and go slow.

 

[sockos]

Re: Broken easyout removal

I've done more of these than I care to remember.
I usually use solid carbide spade bits. Spade bits cuts slower, but are much stronger.
Nice moderate speed, but just as important is rigidity. As stated by others carbide is brittle, any vibration, or side tweeking will break it immediately. Bolt the part down if possible use of a drill press even better! Good luck.

 

[SPOONMAN1]

Re: Broken easyout removal

Socko, the bit I used was a carbide insert on a straight fluted shaft, a "spade" may have been the proper name. It worked like a champ, it is drilled, tapped, and screwed. Thanks Spoon

 

[ehenry]

Re: Broken easyout removal

happened to me once on a water pump bolt on a 350 chevy. Tried the drill thing with the carbide bits...couldnt make it work.....in a quiet desparate rage, I smacked it with a ball pein hammer and a cold chisel......busted the ez-out right out ! I then drilled the bolt out and retapped.

 

[jonesg]

Re: Broken easyout removal

happened to me once on a water pump bolt on a 350 chevy. Tried the drill thing with the carbide bits...couldnt make it work.....in a quiet desparate rage, I smacked it with a ball pein hammer and a cold chisel......busted the ez-out right out ! I then drilled the bolt out and retapped.

yeh brittle like glass.

 

[j_martin]

Re: Broken easyout removal

happened to me once on a water pump bolt on a 350 chevy. Tried the drill thing with the carbide bits...couldnt make it work.....in a quiet desparate rage, I smacked it with a ball pein hammer and a cold chisel......busted the ez-out right out ! I then drilled the bolt out and retapped.

yeh brittle like glass.

Just be durned sure you wear safety glasses.

John