Drilling out a broken bolt

iwaterdave

Petty Officer 2nd Class
Joined
Jun 8, 2012
Messages
109
I'm looking for tips on drilling out a stainless hardened bolt from a softer cast or aluminum cylinder head. The few times I tried the bit moved over to the softer material and now the hole is in the wrong place to be tapped. I've screwed up 3 holed and trying to be super careful. I'm rebuilding this outboard but am breaking bolts off in many places... Helpful tips welcome.
 

wrench 3

Commander
Joined
Aug 12, 2012
Messages
2,108
If you can get a mig welder, hold a nut in position over the broken bolt, you can go one size larger than the bolt if necessary. Weld through the center of the nut to attach it to the bolt. A standard steel wire will weld to stainless. The heat from the weld will help loosen the bolt and the nut gives you something to get a hold of. A bonus with the aluminum casting is that if you mess up and hit the aluminum the weld won't stick.
 

Seahawk170

Seaman
Joined
Jan 16, 2016
Messages
56
I feel for you..been there done that. Best results is starting with a much smaller drill bit, about 1/4 the diameter of stud you're drilling out, and of course taking care to center punch as close to center as possible. Then step up to larger bits and keep fingers crossed. Then heat stud red hot.. I've had better success with MAP gas over propane. After heating allow to cool for about an hour then apply some penatrating oil and allow it to completely cool overnight. The contraction occurs after cooling. Then using a straight fluted extractor sized for last drill bit, lightly tapped down into hole, gently turn extractor a few degrees left & right, being extremely careful not to break extractor. Its a very slow process that cannot be rushed, so patience is a virtue with this job.
If extractor is to break, then its off to a machine shop that has an EMT or similar machine to burn out that broken hardened extractor.
I wish you the best of luck, as this type of project can be extremely aggrivating, and is a true test of one's patience.
 

Rickmerrill

Senior Chief Petty Officer
Joined
Mar 13, 2014
Messages
686
First, try everything possible to not break the bolts off. Soak it (for a long time), rap it, heat it, repeat. Depending on the size of the bolt you'll get a "feel" for how much you can crank it before it will break off - stop before you get there.

If you've already broken it (now you're a hammer mechanic!): As a maintenance machinist I've seen it all. If any of the stud is still sticking out it's a good idea to take a file and make the top flat (easier to center punch accurately). You need to get a fairly sharp center punch dead center. Start with a light tap and look at it. If it's off you can move the dimple around by putting the center punch at an angle and hitting a little harder. Don't start drilling until you know it's dead center!

Next, start with a small drill and only drill a tiny bit out. Stop and check. If it looks off you can correct the hole's direction by drilling at an angle, early on, if you see you're not going right down the center this is the only time to fix that. Once you have a small hole that's centered all the way through you can start gradually using larger and larger drills. With the small drill you want to go slowly, pull the bit out to clear out the chips, maybe a little oil to help keep things cool and help in cutting. You do not want to break off a drill in the hole so go easy!

At some point you might try a screw extractor (if you can get a large enough hole to fit the proper sized extractor with still enough meat on the side walls of the bolt). If the bolt is small a small screw extractor is very likely to break inside the hole - you don't want to do that so stop before you do! If the wall thickness is too thin the extractor will put pressure on the outside wall and you won't get the bolt out. Don't expect the extractor to work miracles but every once in a while it does work but consider yourself lucky if it does.

Often you'll just need to drill out the bolt almost to the edge of the inside threads of the hole. Once you are close you can use a few small sharp tools "picks" to unwind the threads - it will come out like a little spring. Once most of the bolt is gone you can chase the threads with a tap to clean it out.

When mechanics brought me a bolt with a drill/tap/EZ-out broken off inside their off-center hole there was no cutting it out (they are hardened steel). We had something we called a "tap burner". It was like a hollow welding rod with fluid running thru it and the arc eroded away the offending hardened miscreant. If you find yourself in that situation you should look for an automotive machine shop that has such a setup.

One more thing. On my old 7.5 hp Elgin outboard the holes for the bolts were drilled thru and threaded. Once I got most of the broken bolts out I was able to drill a thru hole and then use a bolt and nut to hold the piece together. Not pretty, but it works just as good! On my newer Evinrude I learned to be patient, use heat, impacts and soak. I didn't have any broken bolts to remove. Both engines were in a salt water environment for many years - finesse and patience, with just a little bit of technique is the key.
 
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Ned L

Commander
Joined
Sep 17, 2008
Messages
2,266
The only thing I can add is if there is any way to get to one, use a drill press rather than a hand drill; and start the hole with a center drill (it will not walk like a drill bit).
With S.S. in aluminum, we trust you are using lots of heat & applied fast just before trying? The Aluminum has a much higher coefficient of expansion than S.S. and will expand away from the S.S. fastener.
 

wellcraft-classic210

Master Chief Petty Officer
Joined
Sep 22, 2010
Messages
839
1+ on the heat -- I like repeating the heat cycle a few times when time allows and soaking in penetrating oil as mentioned above.

Also -- Be aware that aluminum melts before its red hot -- so if your using a welding torch be cautious -- Map gas would offer less risk for that.
 

Ned L

Commander
Joined
Sep 17, 2008
Messages
2,266
Also -- Be aware that aluminum melts before its red hot -- so if your using a welding torch be cautious -- Map gas would offer less risk for that.

Good point,... Aluminum is pretty much like ice, (goes from solid to liquid with not much in-between)
 

gm280

Supreme Mariner
Joined
Jun 26, 2011
Messages
14,604
Odd iwaterdave hasn't responded back on this thread. Maybe if he reads this, he could post some pictures of what he is dealing with.
 
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