Broken Bolt Removal Ideas?

[gojayo]

So far, in removing my OMC Stringer 800 I've broken 7 1/4" bolts, most of them flush with the corroded aluminum housings they tap into.

Many are tapped deep, like 3/4" or so. I can see that chaulky aluminum oxidation all over. I've used the straight side easy-outs before, and in 1/4" bolts I bet I've broken 2 easy-outs for each successful removal of a broken bolt.

Please anyone: Offer whatever tricks you've used that work!

Thanks to all. Jay in Seattle

 

[mkpj1]

Re: Broken Bolt Removal Ideas?

Geez, 7! what's the cost for a new housing as opposed to a lot of easy outs? I have one break and i'm cussing cause getting one and retapping is a pain. those are in steel.

You break one okay, two...you need to re-think your technique. in my opinion easy outs suck! soak em, heat em, something but don't just break them.

Can you weld? If you can you can take a nut a little smaller and put weld into the hole essentually making another head. Also, The heat "may" loosen the hold on the bolt enough to loosen it up. Becareful with aluminum and heat though. I have heard of some using nitric acid if the bolt is steel as the nitric acid will eat the steel and not touch the aluminum? do a search!

Your only other option is drilling and in worse case scenario retapping to the next size bolt.

 

[ziggy]

Re: Broken Bolt Removal Ideas?

what are the bolts made out of?

i had 3 ss bolts break off in my upper a few years ago. i remember drillin them completely out like it was yesterday. i hope there not ss as they're a real bummer to drill out if they are. but it can be done. i bet i spent 20 hrs + drillin 3 bolts out. + in the end i had to helicoil them. drill em straigt too or ya'll be sol.
whatever ya do. don't break off a tap or a drill bit or a broke bolt extractor in the broke off studs. that'll stop ya cold too.......good luck......

 

[MtnBoater]

Re: Broken Bolt Removal Ideas?

This probably isn't the best technique for many applications, but I've loosed many a stuck or broken bolt with a mapp gas blowtorch. I've also had luck by cutting a small notch in the head of whatevers left and using a impact driver(the kind you hit witha hammer) with a small flathead bit. Otherwise, drill it out and re-tap, really not that big a deal, unless you have to do 7 of em!