bluemach1

iTrader: (2)

I broke a Torx T-40 in the bolt while installing the cam retainer plate. Was only doing 11 Ft. Lbs. Crap "powerbuilt" tool. Now the torx is broken flush with the socket of the bolt. Can drill it. Bits hardly scratch it.

I guess the tool is twisted enough in there that is bound in pretty tight.

Thoughts on how to get this out?

msydow

try to knock it loose with a punch...other than that i got nothing.

bluemach1

iTrader: (2)

Thried that. I think it is just jammed in there tighter...

Mart00SS

iTrader: (19)

You could try heating up the bolt head with a torch and try to pop it out. Other than that drillling is probably your only other option.

M6Z28

iTrader: (13)

Can you get a vice grip on the bolt to take it out?

bluemach1

iTrader: (2)

Yep. Tried heating it. Again, it I think the only thing I did was wedge it in more.

What is left of the tool is broken flush. Cant grab with vice grips.

Since it is a tool, the steel is extremely hard. my drill bits just spin on it...

M6Z28

iTrader: (13)

I meant the outside of the bolt, not the torx

vettenuts

iTrader: (4)

Not sure how you heated it but the rubber on the other side can be damaged with too much heat. What kind of drill bits are you using, you may need a different bit type. I would test bits on the other part of the tool (not the part on the motor) until you find something that works.

Also, when you yield a material such that it fails, it hardens in the process.

BADD SS

iTrader: (4)

You should be able to drill it with a quality cobalt bit, If not an old trick I used to do is take a masonry bit, grind a regular drill bit angle into it on a bench grinder (they are made for chipping), and go very slow with lots of oil. It will go through most metals, even hardened stainless, but is very very slow. Personally, I would tig a piece of metal to it and try to get it out. I had this same problem happen to me before, but I was always able to drill out the center of the torx, and pop it out.

miker2

iTrader: (1)

you can use a dremel with a cutoff wheel to cut a slot across the head. then if the torx driver still doesn't come out,you can use a screwdriver bit in an impact driver.

Bramlok

iTrader: (7)

It doesn't sound like the bolt is in too tight when the bit broke. You can try something that's worked for me in the past.

You'll need a good sharp chisel and a hammer. Set the chisel at the edge of the bolt and hit it counter clockwise with that hammer. You might be able to get it moving and back it out that way.