1BADCTS

iTrader: (17)

Broke a #2 easy out trying to free a broke stuck bolt. I will never do this again... Left hand drill bit is what I should have done. Anyways... Pounded the crap out of the broke peice with a punch thinking it would shatter, now it's just deeper in the hole.

Any ideas? Anybody ever use a rescue bit ??

Creative Steel

Not sure where you broke the bolt at, but is it possible to weld a nut to it?

1BADCTS

iTrader: (17)

The 6mm (very small) bolt is broken ~1/4" below the surface/plane of the aluminum boss. I don't think I can manage a weld with the small amount of workspace + deep depth of the break.

BudRacing

iTrader: (3)

Drilling it out and re-tapping may be your only option.

neveret

iTrader: (1)

you can't drill into an easy out so you'll have to grind it out just like in the video or with another high speed grinder and bit combo.

Choppy_Idle

I can´t believe, that there is a grinder or miller like the rescue bit out in the whole world, which can resist a screw tap or something like that in the Video!

Every material which is harder then the screw tap is also so hard, that it will break when you come in bad angle or something like that while you were grinding it out!

The only thing that may work is industrial Diamond grinder, this will work over hardness 60 HRC, my Job tells me in experience over 25 years now doing similar things like your pain now!

A broken screw tap in a deep whole is nearly impossible to come out without a collateral damage!

Or wire-electro discharge machining can do this Job, but ist expensive i think?!

Sorry for bad News, wish you all the best and good luck,
Ronald

G-Body

iTrader: (4)

Sounds ugly. I broke a cobalt drill bit off in the shock mount of the lower control arm. Burnt up half a drill bit set drilling through it.

Other than grinding it out with a carbide bit the only thing I can think of is maybe heat the aluminum up and hope it expands faster than the easy out, maybe you can back it out that way.

Any pics of what your working with?

1BADCTS

iTrader: (17)

Thank you for the ideas guys, I'm listening.

At this point I would be embarrassed to show what it looks like. I will take a picture tonight just so you get a laugh. Beating on the busted piece with a hammer/punch hoping it would shatter actually cracked the aluminum boss which is why I stopped doing that... and drilling a second small hole beside the original , hoping I could pry it over and twist it out... ugh, it's ugly.

At this point, IF I can get the easy out reamed out with the rescue bit, I'll have to fill the boss with JB weld, or SteelStik or something, re-drill the hole, and helicoil it. I don't know what else to do.

I agree with the guy above... I'll have to be careful because I'm sure this bit will be even more brittle than a tap or easy out.

raven154

iTrader: (14)

Since the boss is already cracked, would it not be possible to just break the boss, remove the fastener, then TIG weld the boss back up then drill and tap the hole?

onebad636

iTrader: (13)

what part is it?

1BADCTS

iTrader: (17)

45 minutes of very careful work with the rescue bit and I managed to ream out the easy out and the bolt. A little more work around the edges but it's mostly there. It's ugly, and due to space I had to do it at a slight angle so screwed up the boss even more, but it is what it is. 3/4" deep into the boss. Now I can start thinking about how to repair the boss. TIG welding is a good idea, I'll have to think on that one.

NIKDSC5

iTrader: (10)

What am I looking at?

rand49er

Hope this works out for you.

(Every time I work on my car, this is the nightmare lurking in the back of my mind.)