Done it now! Broke head bolt off

[bigwahoo]

I have messed up! Trying to remove head of my 25 evinrude I broke one head bolt off flush with the block. No problem until I broke extractor off in the bolt. Any ideas guys. Thanks!

 

[Walter]

Re: Done it now! Broke head bolt off

Uh-oh...<br /><br />Extractors are generally made of hardened steel and don't drill out easily. Sometimes a cobalt bit will do the job...but keeping it straight is the key.<br /><br />Good luck...<br /><br />Walt

 

[bigwahoo]

Re: Done it now! Broke head bolt off

Walt, Thank you very much! I will give it a try. Ben

 

[stilllearning6]

Re: Done it now! Broke head bolt off

This is what I 've read in the auto forums -- Weld a large hex nut to the broken bolt . Allow to cool thoroughly . In theory , when the weld heats the broken bolt area, the bolt will expand , thus enlarging slightly the hole that it is in. Then , when it all cools , the bolt shrinks more than the hole and the hex nut gives you something to grab . I never did this . Just read it .

 

[JB]

Re: Done it now! Broke head bolt off

AAAUUUUGH!!! I HATE it when that happens! You have my sympathy Bigwahoo.<br /><br />I really like Stilllearning's suggestion. Never heard that before, but wish I had thought of it at least half a dozen times.<br /><br />Red sky at night. . .<br />JB

 

[BayStLouis]

Re: Done it now! Broke head bolt off

Ouch! Been there a time or two. Make friends with a local machinist, they see those "special problems" all the time.<br /><br />The "weld a nut to it" trick does indeed work - if the broken shank really is flush with the cylinder deck. Of course, if you got the EZ-out in there a bit crooked and locked the threads, things are a lot more gloomy.<br /><br />Here's another trick: Find a set of left-hand-twist drill bits. If you can get a hole started with a cobalt bit (doubtful), then switch to the left-hand-twist bits. Use a reversible drill and the broken shank might - *might* back itself out of the hole. The counter-clockwise rotation of the drill will tend to back it out, not send it further down the hole. Depends on how badly corroded those threads are.<br /><br />Good luck.<br /><br />- BSL

 

[JB]

Re: Done it now! Broke head bolt off

Let's bump this up. I want to know how and when Bigwahoo solves this.<br /><br />Red sky at night. . .<br />JB

 

[SS MAYFLOAT]

Re: Done it now! Broke head bolt off

Here is an idea that I had used once when I fudged up a broken bolt with a broken extractor or tap. This will only work on aluminum cases and where you have plenty of material to work with. I have used what the carpenters call a plug bit. They use these to make wood plugs for dowell pins in furniture. Get one that will fit over your broken catastrophy by a 1/16. If it is a 3/8 bolt then use a 7/16 bit. Now this will crate a lot bigger hole, but then you can tap it out and install a insert for your new head bolt. The plug bit will completely enclose the broken part within the inside of the bit. Just make sure your plug bit does not come in contact with any steel part. It will destroy the bit. It will take a little bit of patientence to get the bit started, but this is the best way I have found to extract a major disaster. But again, you have got to make sure that you have enough material to allow for the bigger hole. I always practice on old parts first, a little experience is better than none at all. Good Luck. I have used the Weld-a-nut method also and it has worked most of the time. If that method of welding does not work, I would suggest the plug bit. One thing I forgot to mention. Once you have the hole drilled to the depth you need, just use a screw driver to bend the plug back and forth until it breaks off, and then pull it out of the hole. The plug bit works like a hole saw without the pilot bit. Good Luck..

 

[bigwahoo]

Re: Done it now! Broke head bolt off

Wow guys, you have come up with some very good suggestions! If I understand the weld a nut solution I cant use it because the bolt is broken off flush with the cylinder block. I have tried the colbalt drill bit without success. The plug bit looks like my only chance. Thanks, Bigwahoo

 

[Backlash]

Re: Done it now! Broke head bolt off

Understand it is a nut that you would weld on to the bolt shaft. You should be able to weld the nut to the shaft through the hole in the nut. I've seen it done.......can be tricky. <br />Backlash

 

[clanton]

Re: Done it now! Broke head bolt off

Try and find welder that has done this before. use mig with gas, make sure that the ground cable is place so that current will not flow thru bearings or cylinders(welder should know this). If welder is great, bolt can be 1/8 inch below surface. Sometimes will have to weld nut on 2 or 3 times. Do not use tig.

 

[evin300]

Re: Done it now! Broke head bolt off

I would get several very small drill bits (1/16th) or so, then start drill around the extractor into the softer bolt untill it looks like swiss cheese. This should remove enough material to get the extractor out. Then you can continue drilling out the bolt, then then use a tap to clean the threads, or if it gets real messy you could use a heli-coil. You could possibly use a extractor again also. I would expect these small bits to dull as they hit the extractor and they do break easy, thats why I say get several, be careful and take your time, and If there is an area where you can use a larger bit, then use it. Good Luck

 

[catfish]

Re: Done it now! Broke head bolt off

this works the same but better. first weld a washer that will fit the bolt on the inside of the washer to the bolt. then weld a nut to the washer. the weld to the washer first gives you more welding area on the bolt and then to the nut. sometimes a second washer the size of the nut<br />welded between thewasher and nut helps so you will not have to grined so much weld off the bolt and washer.

 

[Beernutz]

Re: Done it now! Broke head bolt off

Back to the top with this wealth of knowledge and experience from the world of busted knuckles! Who hasn't been here before with salted or galled stainless steel bolts? Thank Sears for cobalt steel drill bits.

 

[bigwahoo]

Re: Done it now! Broke head bolt off

Hey guys,I have found an expert welder who has done many of these though he would prefer not to have extracter in bolt but can do it. He charges $50.00/ hr with a 1 hr min. It that price ok or a bit high? I look forward to you replies. Thanks again, Ben

 

[JB]

Re: Done it now! Broke head bolt off

Go for it, Ben. I hope he guarantees his work.<br /><br />Red sky at night. . .<br />JB

 

[Firewood]

Re: Done it now! Broke head bolt off

I'm late to this post but I have broken eazy-outs off before. They are so hard and brittle sometimes I was able to hit the eazy-out with a punch and shatter it. then you have to get the pieces out of the bolt. I always try and drill the biggest hole possible into the bolt so I can obviously use the largest/strongest extractor I can fit. I really SUC#S when then happens .....good luck. Where do you live? My brother in-law is an ace welder. Easter Long Island,NY.

 

[bigwahoo]

Re: Done it now! Broke head bolt off

Thanks, Ill try one more time before I cough up the fifty bucks. Long Is a little far but thanks for the try. Ben

 

[shakespear]

Re: Done it now! Broke head bolt off

Hope this helps there are special welding rods for this problem try local welding supplier. they are expensive but do work<br />they have a special coating that prevents weld from destroying metal to the sides of sheared bolt. any resonable welder can use them. good luck!!!

 

[keepa]

Re: Done it now! Broke head bolt off

I would like to pass on a trick that has saved me alot of aggravation in the past. When you have encountered a seized fastener and can not get it to budge, try gulf wax. It is sold in the grocery store for canning. Heat the bolt and surrounding area with a propane torch enough to melt the wax. Capalarie attraction will pull the wax into the threads just like soldering a joint does solder. Shock the bolt with a blow from your hammer then try to loosen it. When it begins to turn, turn it counter clockwise then clockwise as you bring it out to help clear the threads. You will be surprised how well this works. I hope this helps you later on before the bolt breaks. Good luck.