Broken bolt extractor...what's next?

gwolever
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Broken bolt extractor...what's next?

28 Jul 2011 23:34

So after slamming my oil pan with a rubber mallet as suggested by some very helpful people here on the forum, the gasket finally gave and took care of that problem this morning.

I then proceeded to remove the valve cover and found most of the bolts in very bad shape. I was able to get all but 2 off. So I had 2 broken bolts to deal with once I got the valve cover off.

Since they were both just below the surface, I center punched them drilled them, and used my handy-dandy bolt extractors. And wouldn't ya know it, the bolt extractors snapped of in there with the broken bolt. Just having all the luck today.

Has this happened to anyone here, and if so, what are your suggestions? I did see online about tap extraction, where they use electricity to crumble the bolts/extractors/bits with no damage to the threads. Supposed to only take seconds. I am going to call around tomorrow to find out if anyone does that around here.

Thanks.

1982 KZ1000 CSR

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Motor Head
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Re: Broken bolt extractor...what's next?

28 Jul 2011 23:41

#465610

Left hand Cobalt drill bit. This will drill into the extractor. Taking it out. then if you drill right the way through the bolt, soak it with a penetrating oil, apply some heat and try another extractor Knowing when to back off without snapping hopefully.

1982 KZ1000LTD K2 Vance & Hines 4-1 ACCEL COILS Added Vetter fairing & Bags. FOX Racing rear Shocks, Braced Swing-arm, Fork Brace, Progressive Fork Springs RT Gold Emulators, APE Valve Springs, 1166 Big Bore kit, RS34's, GPZ cams.
1980 KZ550LTD C1 Stock SOLD Miss it
1979 MAZDA RX7 in the works, 13B...

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testarossa
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Re: Broken bolt extractor...what's next?

28 Jul 2011 23:52 - 29 Jul 2011 00:06

#465611

The process of burning out broken taps is known as EDM. It will also work on your screw extractor. In the end, it will probably be worth it to have the extractors burned out. Sure beats screwing up threads and having to deal with that.

Actually if you were going the route that Motorhead suggests, you need a right hand drill. The helix of the extractor is left hand to extract the screw with right hand threads. If you turn it to the left then it will try and further bury itself into the broken screw. The left hand drill trick sometimes works on the broken screw itself. If you drill directly into the screw with the left hand bit before you try the extractor.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

Last edit: 29 Jul 2011 00:06 by testarossa.

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650ed
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Re: Broken bolt extractor...what's next?

29 Jul 2011 00:09

#465617

Too late now, I know, but for future reference if you are trying to extract a bolt that's really stuck soak it with Kroil for a couple days and you'll be amazed at how easily it can be removed. Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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steell
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Re: Broken bolt extractor...what's next?

29 Jul 2011 00:47 - 29 Jul 2011 00:48

#465630

" Excellent advice. I need to find some people I don't like to give my screw type "easyouts" to. I have found them to be less than useless. Withe the bolt seized so tight that it broke off, what chance does an easyout of less diameter have?

That's what you do with EasyOut type screw extractors.

Back to getting the bolt and extractor out.

Here's an entire thread on dissolving a steel bolt that broke off in a aluminum casting using alum, which can be found at grocery stores with the canning supplies.

Alum thread

It works and doesn't harm aluminum, might take all weekend though, so go fishing.

Can I have a show of hands of those that have successfully drilled through a broken easyout in aluminum?
I assure you my hand won't be raised.

KD9JUR

Last edit: 29 Jul 2011 00:48 by steell.

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TexasKZ
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Re: Broken bolt extractor...what's next?

29 Jul 2011 17:05

#465732

Back to getting the bolt and extractor out.

Can I have a show of hands of those that have successfully drilled through a broken easyout in aluminum?
I assure you my hand won't be raised.

Let's see, IF you can get the part snugly in a vice or lathe chuck so that the broken EO is perfectly perpendicular to the drill press or headstock on the lathe, and IF you can get a carbide centering bit to actually start a hole in the center of the ragged part, and IF you can then get a relatively large carbide drill bit to drill into the broken EO, and IF it does not cause the broken bolt to strip the threads in the aluminum, then I reckon there is a greater than 1% chance of getting this to work.

Neither of my hands is up.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/11-projects/620336-anoth...uild-thread?start=24

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Patton
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Re: Broken bolt extractor...what's next?

29 Jul 2011 19:33

#465743

OMR's hand was up . . . until he broke off the carbide drill bit inside the easy out. :ohmy: :pinch: :laugh:

1973 Z1
KZ900 LTD

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lemo32
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Re: Broken bolt extractor...what's next?

29 Jul 2011 20:45

#465754

If you didnt break the ez out completely flush with the bolt, meaning just a tip of the extractor is broken off, you can try a smaller drill bit and drill the alum out from around the extractor, if its flush, your pretty much screwed, I broke one of those nasty suckers off in a set of cases once, got lucky enough to drill around it and get it out, then i took it to a machine shop they filled the hole up and drilled and retapped. I never use those things after that.

1979 kz 1000 06 katana 750

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testarossa
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Re: Broken bolt extractor...what's next?

29 Jul 2011 22:54

#465780

steell wrote: Can I have a show of hands of those that have successfully drilled through a broken easyout in aluminum?
I assure you my hand won't be raised.

I have drilled through a pair of broken easy outs in a a pair of brass carburetor jets. I chucked the offending carbs in a mill vice, and drilled through the easy out with a ball nose carbide endmill. Saved a set of VM29 smooth bores that way. I do make a living as a machinist. Probably not your average garage repair, for sure.

This link will take you to page 81 of my build thread where I documented the repair: Carbide defeats tool steel once again

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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gwolever
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Re: Broken bolt extractor...what's next?

30 Jul 2011 01:04

#465795

Drills aren't doing a thing against those broken extractor tips.

Luckily, after calling around for about an hour, I found one shop here locally that has an EDM. He told me to bring in the cyl. head and it wouldn't take long at all to burn the holes clean.

So now to take out the camshafts to pull off the cyl. head.

Hopefully I don't have any more bolts break when taking off the head.

Thanks for all the input guys.

1982 KZ1000 CSR

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harleygirl33
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Re: Broken bolt extractor...what's next?

05 Aug 2011 03:22

#466976

I got a broken extractor out of my boat exhaust head the hard way - had to remove the old broken bolt surrounding the busted extractor - with diamond dremel bits. Slow going - spent probably 10-15 hours doing this (1/4" diameter bolt) and about 30 diamond bits. They were cheap, on sale at Princess Auto 20 for $10. Helicoiled it after. I think I got lucky tho. Was able to sit to work on it- at eye level in an easily accessible area- bought a light with a magnifier on it so I could see good. Lots of patience required - lots! Spent a lot of time researching this dilemma online first and unable/unwilling to take anything more apart to pay someone else to deal with. No EDM available around here either. Did this over several evenings - if you try - quit each session before you get too upset. You have to be super careful to not let the tool slip onto the aluminum case. Used a plastic tube taped to the shop vac to remove metal shavings as I went. Frustrating, but got er done! Pretended I was a dentist,..lol Would definitely do EDM if it were available, but also I don't think they can guarantee that it will work.

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jonnybravo
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Re: Broken bolt extractor...what's next?

05 Aug 2011 08:30

#466985

harleygirl33 wrote: I got a broken extractor out of my boat exhaust head the hard way - had to remove the old broken bolt surrounding the busted extractor - with diamond dremel bits. Slow going - spent probably 10-15 hours doing this (1/4" diameter bolt) and about 30 diamond bits. They were cheap, on sale at Princess Auto 20 for $10. Helicoiled it after. I think I got lucky tho. Was able to sit to work on it- at eye level in an easily accessible area- bought a light with a magnifier on it so I could see good. Lots of patience required - lots! Spent a lot of time researching this dilemma online first and unable/unwilling to take anything more apart to pay someone else to deal with. No EDM available around here either. Did this over several evenings - if you try - quit each session before you get too upset. You have to be super careful to not let the tool slip onto the aluminum case. Used a plastic tube taped to the shop vac to remove metal shavings as I went. Frustrating, but got er done! Pretended I was a dentist,..lol Would definitely do EDM if it were available, but also I don't think they can guarantee that it will work.

welcome to the forum

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