Broken bolt removal - some new tricks?

[Paul Workman]

Having (again) recently encountered a broken bolt, snapped off deep inside an aluminum manifold (no, not one of my manifolds, thank goodness), I found this new (to me) methods for removal. It was new to me, and there have been times when I wound up destroying the hole and had to weld and re-tap the bolt hole.

Anyway - just thought maybe one of us DIY'ers might benefit from this. Enjoy!

https://www.youtube.com/watch?v=dJfkCj3FWBs

[WARP TEN]

Paul, you are right it is a great video to help anyone who has encountered or might encounter the dreaded broken steel bolt in aluminum. Many moons ago when I was a teenager and a Mercury Outboard mechanic, I ran into a number of such situations when dismantling outboards because we were running in salt water which really aggravated this problem with dissimilar metals screwed together. I could have used this knowledge then!

It would be helpful if someone made those socket head bolts with the holes in them and you could get them commercially. He said he made his own on a lathe, which not everyone has access to, although it probably wouldn't be to much of a problem to get a friendly machine shop to make a few. I don't think I will be running into any more steel bolts snapped off in aluminum but it sure should help anyone who will. --Bob

[Dynomite]

The key is the use of Left Hand Drill Bits followed by a Left Hand Easy Out Extractor Set

Left Hand Drill Bits (https://www.ebay.com/sch/i.html?_from=R40&_trksid=p2380057.m570.l1313.TR8.TRC2.A0.H0.Xleft+h and+drill+bits.TRS0&_nkw=left+hand+drill+bits&_sacat=0)

Easy Out Extractor Set (https://www.ebay.com/sch/i.html?_from=R40&_trksid=m570.l1313&_nkw=easy+out&_sacat=0&LH_TitleDesc=0&_osacat=0&_odkw=easy+out&LH_TitleDesc=0)

This will work on bolts counter sunk or broken off flush. A bit of shocking or heat followed by WD-40 will help :thumbsup:

Use a center punch to shock and center for drill bit.
(I think all you need is a Drill Press to place a center hole of any size in a Socket Head Bolt of any size as a guide).

After use of left hand drill bit, clean out the threaded hole and apply WD-40 before using the Easy Out Extractor.

[RussMcB]

Thanks, Paul. Good video.It would be helpful if someone made those socket head bolts with the holes in them and you could get them commercially. Bob, I agree, It seems unfair that he only needed 8, 10 & 12mm sizes. :-)

[tnova]

Great tips, especially the hinge drill tool

[Dynomite]

It would be helpful if someone made those socket head bolts with the holes in them and you could get them commercially. He said he made his own on a lathe

I think all you need is a Drill Press to place a center hole of any size in a Socket Head Bolt of any size as a guide :p

[Paul Workman]

I think all you need is a Drill Press to place a center hole of any size in a Socket Head Bolt of any size as a guide :p

Got me to thinkin' (Oh, oh...!)

A cap screw (bolt) would be ideal perhaps. But, maybe hard to come buy, in some cases.

However, any bolt would work if first set into a (metal) plate before using a drill press (and a carbide tipped drill bit).

Have to give that some thought...

[BigJohn]

We used to use left hand drill bits