Author Topic: Broken bolt removal  (Read 2663 times)

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Offline Cut4fun .

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Broken bolt removal
« on: July 29, 2011, 06:50:02 pm »
I have some non chainsaw projects that the bolts are broken off flush with casing. What is the easiest way to remove? I'm thinking of trying a EZ out.

Never used so how do they work or any other ideas. 
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Offline rgclmc

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Re: Broken bolt removal
« Reply #1 on: July 30, 2011, 11:07:00 am »
The best luck I've had is with a left handed drill bit, if you can find one.

Offline Playinwood

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Re: Broken bolt removal
« Reply #2 on: July 30, 2011, 11:59:19 am »
I second a left handed drill bit but try a prick punch and hammer,if it comes easy continue but if its tough use the drill bit.
The secret with the LH drill bit is once you are in about an 1/8th put downward pressure on the drill motor so the "edge" of the bit contacts the side of the hole. This will cause you to jam the bit and instead of the bit spinning will cause the broken bolt to wind its way out.Aluminum is pretty soft and usually comes out fairly well.

If that doesn't work, continue hole completely through broken section and use as a pilot hole with EZ out...

Offline man of stihl

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Re: Broken bolt removal
« Reply #3 on: July 30, 2011, 12:23:35 pm »
I have some non chainsaw projects that the bolts are broken off flush with casing. What is the easiest way to remove? I'm thinking of trying a EZ out.

Never used so how do they work or any other ideas. 
How big is the bolt? EZ outs work good. you drill a hole through the bolt. The EZ out is tapered, so you beat it into the hole you just drilled. The part that you hammer in has backwards cutters that dig in when you unscrew the EZ out.
Ron

Offline Cut4fun .

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Re: Broken bolt removal
« Reply #4 on: July 30, 2011, 02:46:29 pm »
Never heard of left drill bits till this. Think I will buy a set of left drill bits and set of ez out to have on hand.   

Thanks.
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Offline farmboy

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Re: Broken bolt removal
« Reply #5 on: July 31, 2011, 10:18:01 am »
I bought my last left hand bits @ Autozone $6?.  Another option is lay a nut one size smaller on top of broken bolt mig/tig inside nut, remove w/ wrench.  On smaller stuff put use a washer slightly smaller tack then weld nut to washer.  Am going to use the last method on 359 muff.   Kid that was helping me broke e-z out off in muff support bracket hole (5mm bolt) me telling him don't pull too hard you will break it.  2 breath's later I heard him cussing.

Shep

Offline Playinwood

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Re: Broken bolt removal
« Reply #6 on: July 31, 2011, 10:59:02 am »
More good advice with the washer and welding a nut on. They work well if you just happen to have a tig outfit hanging around.


One more, on larger bolts, drill pilot hole just slightly smaller than broken object, then take small center punch or chisel and collapse broken section towards the center of the hole, once a small piece is removed it relieves outward pressure and the remainder seems to screw right out.

Offline Old Iron Logging

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Re: Broken bolt removal
« Reply #7 on: July 31, 2011, 02:52:28 pm »
Buy a set of extractors, you will never regret the money spent.

Offline Al Smith

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Re: Broken bolt removal
« Reply #8 on: August 01, 2011, 12:54:29 pm »
You can "peck " them out with a prick punch or a skinny drill bit shapened like a prick punch .It helps to give them a good soaking first with Kroil or PB blaster .

Often times however and especially on an old saw the darned bolt is captured by corrosion or galvanic action caused by dissimilar metals .It might not hurt to warm the aluminum around the bolt a tad because the aluminum will expand faster than the steel bolt .

Worst case when all fails is drill and tap for the next sized bolt ,often the only option .Not the first time nor the last .

Offline farmboy

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Re: Broken bolt removal
« Reply #9 on: August 02, 2011, 01:53:47 pm »
I have made my own extractors by grinding a bolt to 4 tapered sides.  Tap in w/hammer use bolt head to remove.  Works good on broken pipe fittings, etc.

Shep

 

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