Broken bolt removal, time to revisit.....

   / Broken bolt removal, time to revisit..... #1  

Oldpath05

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So I have a couple broken bolts on my wood splitter, 5 hp Briggs exhaust muffler, 25 years old so the muffler was falling apart and almost zero hr to get this splitter rocking. Of course the bolts broke when taking off the muffler, be shocked if they didn't, only 1/4" bolt, bout 5/8 deep. Then tried the weld nut trick, broke off again about 16th below surface on aluminum head, now I get a little nervous, so I decide to drill, first with 5/32, for the heck of it put an extracter in and put a little pressure on, I said nope wont chance that breaking, since I had it drilled fairly centered I redrilled with 3/16", the existing threads that was left could just barely make out so I was satisfied with that one. Now the next one tomorrow, might try the washer weld then weld nut trick and see what that does while it's still above surface.

So where do people go nowadays when they have a mechanical problem, right youtube and or TBN and youtube it is full of this bolt removal stuff, most of it I already knew except for this one, never knew this machine existed, some sort of molten metal bolt removal machine, quite the tool. Broken Easy Out Inside a Broken Bolt - Extraction - Part 1 - YouTube
Broken Easy Out Inside a Broken Bolt - Extraction - Part 2 - YouTube
 
   / Broken bolt removal, time to revisit..... #2  
Tap disintegrator. We had one at Pfizer because people would break stainless bolts off in very expensive workpieces. The nicest thing was we could use it on personal jobs after work time!
 
   / Broken bolt removal, time to revisit..... #3  
A wax candle or something with wax is your friend in this case. Just weld the washer on and then touch the area around with the wax. The wax will flow into the treads and lubricate them. Then weld your nut on and do the same thing with the wax.

Put a flat wrench on the nut and start to work the stud back and forth. Most times after a few minutes you will start to get movement. Taping the edge of the casting with a hammer where the bolt is also helps. It also helps to tap the top of the nut a few times. Keep working the wrench back and forth. Once you fell a bit of movement you've won the battle. If you nut breaks off start over. I've never had a broken off stud that I couldn't remove doing this. Most times I can get the threads out with one welded nut. Sometimes it takes two but I've never had to weld on more than three nuts. Lots of wax is your friend!
 
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   / Broken bolt removal, time to revisit..... #4  
If and when you get those broken studs out; when replacing the muffler use brass nuts and a heat proof thread lubricant. Brass nut are the most common way to secure exhaust system bolting. The extreme heat does not cause the brass nuts to corrode. Brass nuts are easy to split with a chisel in the future also.

Ron
 
   / Broken bolt removal, time to revisit..... #5  
So I have a couple broken bolts on my wood splitter, 5 hp Briggs exhaust muffler, 25 years old so the muffler was falling apart and almost zero hr to get this splitter rocking. Of course the bolts broke when taking off the muffler, be shocked if they didn't, only 1/4" bolt, bout 5/8 deep. Then tried the weld nut trick, broke off again about 16th below surface on aluminum head, now I get a little nervous, so I decide to drill, first with 5/32, for the heck of it put an extracter in and put a little pressure on, I said nope wont chance that breaking, since I had it drilled fairly centered I redrilled with 3/16", the existing threads that was left could just barely make out so I was satisfied with that one. Now the next one tomorrow, might try the washer weld then weld nut trick and see what that does while it's still above surface.

So where do people go nowadays when they have a mechanical problem, right youtube and or TBN and youtube it is full of this bolt removal stuff, most of it I already knew except for this one, never knew this machine existed, some sort of molten metal bolt removal machine, quite the tool. Broken Easy Out Inside a Broken Bolt - Extraction - Part 1 - YouTube
Broken Easy Out Inside a Broken Bolt - Extraction - Part 2 - YouTube

That looks great! Can I get it at Harbor Freight for $5.99?
 
   / Broken bolt removal, time to revisit..... #6  
So I have a couple broken bolts on my wood splitter, 5 hp Briggs exhaust muffler, 25 years old so the muffler was falling apart and almost zero hr to get this splitter rocking. Of course the bolts broke when taking off the muffler, be shocked if they didn't, only 1/4" bolt, bout 5/8 deep. Then tried the weld nut trick, broke off again about 16th below surface on aluminum head, now I get a little nervous, so I decide to drill, first with 5/32, for the heck of it put an extracter in and put a little pressure on, I said nope wont chance that breaking, since I had it drilled fairly centered I redrilled with 3/16", the existing threads that was left could just barely make out so I was satisfied with that one. Now the next one tomorrow, might try the washer weld then weld nut trick and see what that does while it's still above surface.

So where do people go nowadays when they have a mechanical problem, right youtube and or TBN and youtube it is full of this bolt removal stuff, most of it I already knew except for this one, never knew this machine existed, some sort of molten metal bolt removal machine, quite the tool. Broken Easy Out Inside a Broken Bolt - Extraction - Part 1 - YouTube
Broken Easy Out Inside a Broken Bolt - Extraction - Part 2 - YouTube

You should get a set of cobalt LEFT HAND drill bits!
They will almost always work.
When you are drilling, you are simultaneously attempting to back out the broken bolt.
 
   / Broken bolt removal, time to revisit..... #7  
I agree with the left hand drill bits working very well.
 
   / Broken bolt removal, time to revisit..... #8  
What you may find on the aluminum is the the threads are galled from electrolysis causing the two dissimilar metals to fuse together from heat and cooling cycles. The wax or penetrating oils might help but I have had very little success in getting these out short of drilling and retapping the hole.
 
   / Broken bolt removal, time to revisit.....
  • Thread Starter
#9  
You should get a set of cobalt LEFT HAND drill bits!
They will almost always work.
When you are drilling, you are simultaneously attempting to back out the broken bolt.

That's what I'm using, I was looking at it again tonight and noticed the first bit was 1/8 then I used 3/16, the 3/16 got a little dull so I touch it up, had to hold the bit just the opposite of right hand drills on the bench grinder, make a few practice swipes then sharpen it.
 
   / Broken bolt removal, time to revisit.....
  • Thread Starter
#10  
That looks great! Can I get it at Harbor Freight for $5.99?

Might be a wee bit more than that, probably that's why machine shops get the big buck. I would've like to of known the cost of that one hole that machinist did, but even it was cheap most people here like will still like to try to remove the broken bolt ourselves, might be the internal Tool Man's Instinct of liking a challenge so that if we do fix something we can jump up and down on the garage floor shouting.......I got it!!!!!!!
 
 
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