broken lower unit bolt

[54bobby]

hey guys, a friend of mine just snapped the head off of one of the lower unit bolts while installing a long shaft extension. the engine is a johnson 1969 25 hp. the bolt snapped with some sticking out. we got the lower off but when trying vice grips to remove the remaining bolt shaft, it started to turn then it snapped off flush. nothing to grab now. what's the best way to go about removing the stainless bolt from the aluminum case? the standard just drill and retap method or is there a preferred procedure? we do have access to a fully equipped shop.

 

[Scott Danforth]

Left handed drills, start small, go larger. Eventually the stub will spin out. Then chase threads. Worst case you need to helicoil

 

[jakedaawg]

TIG weld a build up and then a nut. Heat breaks the oxidation and they turn out. I have done it successfully many times.