Has anyone sucessfully...broken bolts

[duped]

Anyone ever remove broken off bolts from the top cover assembly on a merc? Whilst changing my yoke seal I decided to remove the top cover and inspect gears, etc, first. I soaked the the bolts in PB blaster, and heated them up, knowing they were corroded. The first two came out clean. The last two snapped off near the head. I made attempts at vise grips, and a small pipe wrench with no luck. I think no amount of care would have prevented this, they are really fused in there!

So I was considering easi outs, but was wondering what everyone else has done in my situation, and if there is any hope?

The gears look to be in EXCELLENT condition, but even then, I'm considering a new SEI upper rather than mess with this one. I use the boat 18+ hours a week and I think it would pay for itself over three years. But just looking for inputs. A sort of "what would you do in my situation"?

 

[45Auto]

Re: Has anyone sucessfully...broken bolts

It's a very common problem, I remove them all the time. TIG weld a washer to the piece of the bolt stuck in the drive (easy to do even if it's below the surface of the drive), then TIG weld a nut to the washer. The combination of the heat and the nut to wrench on will let you screw it right out.

 

[Bondo]

Re: Has anyone sucessfully...broken bolts

The combination of the heat and the nut to wrench on will let you screw it right out.

Ayuh,.... Do you ever Quench 'em, when they're still just welded Hot,..??

I get nervious heatin' fasteners in Aluminum housings,....
Things get Lookin' pretty good,+ the housing falls away,...
SSteel fasteners don't color like steel when you heat it either,...

If ya go the Easy-out route,.... Drill ALL the way through the fastener,...
Not just a pocket for the easy-out...

 

[Bt Doctur]

Re: Has anyone sucessfully...broken bolts

And if you broke a 3/8 ths bolt that was SS ,I`d opt for drilling and tapping

 

[45Auto]

Re: Has anyone sucessfully...broken bolts

The aluminum around the broken off bolt doesn't get very hot, it doesn't even get warm enough to affect the paint. The aluminum is a massive heat sink and the TIG (usually a 1/16" electrode) keeps the heat very localized to a pin point on the broken off bolt and the washer. I've used filler rod to build up bolts broken off about 1/4" below the aluminum surface far enough to weld the washer to them with no problem.

Couple of pics here, this guy uses a slightly different technique. I prefer to weld a washer to the broken bolt then the nut to the washer:

http://weldingweb.com/showthread.php?t=31039

This looks more like the way I do it:

http://idisk.mac.com/forever4/Public/pages/studremoval.htm

 

[Bondo]

Re: Has anyone sucessfully...broken bolts

Ayuh,... I gotta try that Tig thing someday,....

I do kinda like the guy in the 2nd link, only with stick or mig...

 

[duped]

Re: Has anyone sucessfully...broken bolts

Well I only own a MIG, but I decided to give it a try anyways. With not much luck. I felt like I got it close a few times but the washer always let loose from the stud. I'm not a welder by trade or anything but I consider myself passable.

So I tried with a #2 easi out ( biggest recommended for that size bolt ), drilled all the way through with the appropriate size bit. Dead centered. Got the easi out in real deep but predictably it still broke off in there. With the failure rate of easi outs I dont even know why I tried.

I may try a few more stabs at welding tomorrow when I havent been sweating like a pig for 12 hours straight! Its about the only option now for the one with the broken piece of junk stuck in it.