What next, when "easyout's" don't work?

[Jstpssng]

Hi, all

I snapped the bolts off which hold the cast iron housing to the motor, for my portable gas water pump. Since then, for the last 6 months I've been applying PB Blaster to the bolt stubs; and have managed to drill the old bolts out enough so that I can see the threads, but still can't get them out. Any suggestions, other than retapping the 5/16 inch bolts out to 3/8 inch?

thanks.

RHW

 

[RalphVa]

You could use a skinny hack saw blade and saw into the threads. Then see if you can pry the bolt remains out to the middle. Think I remember doing this eons ago. Fortunately, I haven't had to do this type of thing in YEARS. It's for you young folks.

Ralph

 

[David Ferguson]

Left Hand drill bits are the hot ticket. I've broken ez-outs in the bolt, but the torque of a left-hand bit has worked everytime for me. Now I always keep a couple in my tool box.

You can order left hand bits at McMaster Carr. Here's a link:

http://www.mcmaster.com/ Just type "Left-Hand Drill Bits" into the search box.

If that fails, then the last resort is EDM machining....

 

[Jimbrown]

Well it is tedious (sp) but take a small rat tail file (hack saw blade)and keep cutting into the threads in one place untill the bolt reminants break free. and then pick them out. yes you may cut into the threads but in most cases it will not matter once you put in the new bolt. Some times you just gotta do what you gotta do. If you have a tap run it thru to clean the threads if not a new bolt in and out a few times with lots of oil will do the same.

 

[CATMAN]

If you feel you did a pretty good job of drilling straight and are centered in the old broken bolt, just try the correct size tap(taper tap or plug tap). A tap will have a tendency to peel out the old bolt material usually. You mentioned 5/16". Do you know if the bolts were fine thread or coarse? If you do ruin the original threads during this procedure, go buy a 5/16" Helicoil set (or Recoil set=different brand) and use its special drill bit and tap and then install an thread insert and you will be back to 5/16" again.

 

[DieselPower]

Some other things in addition to the above are.

If you have a dremil tool you can split the bolt in two. You already have it drilled out in the center. Now use a dremil tool and a very small dental style carbide burr and run the length of the bolt cutting out the threads on two sides. Once you have the majority of the metal removed in two spots you can simply take a small punch and dislodge the two halves of the bolt.

If all else fails and you damage the threads you can drill it out and install a Time-Sert or Helicoil thread repair of the same size. When you use thread repairs it requires you to drill the hole out oversize, tap the hole and install the insert. No need to go to the next larger size.

I have never been a big fan of "EZ-Out's". They never really worked very well for me because as you tighten them into the broken bolt they tend to expand it at the same time making it even tighter. The broken bolt extractors I use are multi-spline type that are driven in with a hammer and cut small groves into the bolt as they are driven in. You then slide the correct collar over it and use a wrench to remove it. The set I have is a Snap On set I have been using for years. Best of all if you break one they are guarenteed.

E1020, Extractor Set, 20 pcs.

 

[john_bud]

You're past this point, but for larger bolts -- you can weld a bolt to the bolt stub. The welding heat will help loosen the stuck bolt and you can get them out (sometimes) that way.

I hate stuck bolts, but old equipment and stuck / broken / stripped fasteners seem to go together.

jb

 

[Timber]

You know what don't even mess with it, just drill it out and re-tap the thread. I don't even mess with easy-outs because if you snap that you cant even drill it out. (harden steel)

 

[RedRocker]

What Catman and Timber said.

 

[LoneCowboy]

helicoil's
you drill the whole thing out, put in this new tap which is sized for the old size and then put that in, then put in your bolt
stronger than new
done it many times on motorcycles.

Heli-Coil ( HeliCoil Inserts ) Helicoils Screw Thread Inserts | Emhart.com

Diamond Fasteners, Inc.: Inserts

that last one has a good explnation of how they work and what you do
TOTALLY worth it

 

[scott_vt]

Afternoon RHW,
Get rid of your snow yet ?

OK I like Catmans and Brian H 's idea ! Either run a tap down through the hole with some cutting oil or as Brian suggests redrill and helicoil tap and then insert new helicoil to get the same size as original. I ended up using this method on my Super A on the starter holes going into the clutch housing, because I couldnt go to a larger diameter bolt. It worked out quite well !

 

[escavader]

Hi, all

I snapped the bolts off which hold the cast iron housing to the motor, for my portable gas water pump. Since then, for the last 6 months I've been applying PB Blaster to the bolt stubs; and have managed to drill the old bolts out enough so that I can see the threads, but still can't get them out. Any suggestions, other than retapping the 5/16 inch bolts out to 3/8 inch?

thanks.

RHW

When i get in this position ,i dig out the welder and tack another bolt to it,between the heat freeing it,and having a bolt to grip with it gives up 99% of the time.I just did this trick with the rear differential drain plug on my old ford.TRYED the strongest impact in the neighbor hood ...nope,pb blaster ,nope torches ...nope,welded a bolt to it...came right out. GOOD LUCK
alan

 

[Seon]

Buy a set of jeweler's file at Harbor Freight or Sears. Then use the the 3 sided file to file 180 degree apart, thru the threads. Once you're pass the threaded part, use the correct size tap which will "bite" into the broke stud, then back the tap out which...hopefully should have the two halves attached to the tap.

http://www.americanjewelrysupply.com/products/jewelry/images/file3.jpg

 

[hazmat]

Drain all fluids & repurpose it as a boat anchor - then buy a new pump. Gotta keep the economy growing.

As a mechanical engineer I'm very aware of all the elegant ways to remove a bolt (as mentioned already above) - EDM, welding, etc. Alas, at home I don't have EDM, welding, milling etc. capabilites - it leads to very frustrating experiences trying to remove busted bolts. I'll have to try the LH drill bits and/or those fancy splined removers. There is nothing EZ about EZ outs.

 

[escavader]

FUNNY,I striped out the head on my atv drainplug tonite...BOY WAS IT TIGHT .Itryed all different types of sockets,even tryed pounding on a smaller metric...no dice.I took the drive shaft out so i could use vice grips ...coulDnt budge it.frustrated and overwelmed i pushed it over to the welder,and carefully welded a bolt to the striped out one.Then after a prayer I pushed on the ratchet just with a pinkee and it wound right out. The heat freed it up.fruuuuubreath a sighof relief THIS TRICK REALLY WORKS GOOD!!!!!!
ALAN