Head Broke Off Bolt...Please Help!!

[dodge man]

The helicoil is the best idea, it comes with a drill bit will put new, original sized threads back in place. Save the drill bit that comes with the helicoil kit and use other drill bits to get the broken drill bit. It will be a ***** to drill out the broken bit, but if you use some high quality drill bits and enough of them you will get it.

 

[KennyV]

When all else fails an Electro Arc Metal Disintegrator will work.
YouTube - Electro Arc Metal Disintegrator
Some machine shops have portable units that can be taken to the field.

Also very user friendly... if you can get to it, QuikCenter Broken Bolt Remover
YouTube - QuikCenter Broken Bolt Remover

 

[Egon]

Put a milling bit on a good drill and with patience a new hole will appear.

 

[Prodirt6000]

Hey guys thanks for all the great replies and ideas,

I did get out the old bolt today. I ended up using a small punch and punched the broken drill bit up over the bolt into the empty part of the hole. (I say up over the bolt because it was upside down). Apparently there wasnt much that broke off the bit I guess. Then I drilled the hole a bit bigger. Next I tryed heating up the casting with the torch and using the easy out to back it out. Had no luck...Didnt want to break another EZ out in there so I stopped. I sprayed the heck out of it with PB Blaster (we got cans and cans of it on the farm...works amazingly!) up into the hole and all around it by the threads. I did this a few times through out the day. Finally I put the torch to it again and used the EZ out with a Cresent wrench on the end of it. The screw finally gave and boy, it turned out hard! Even with all that leverage from the wrench. Yup so thats my story.

Thanks again guys!

 

[Scotty370]

That's Great!! I hate that 'moment-of-truth' period, when torquing an E-Z out! You know the one: Bolts going to move, or tool's gonna 'snap'!

 

[Egon]

Good show. Perseverance with tradition methods just may be the ticket!

 

[boxygen]

Congratulations, this is the type of project that can take years off your life sometimes! I've had good luck with PB blaster in the past. I had a brake rotor rusted to the hub of my truck. Sledge with 3'handle and full swings wouldnt remove it. Pipe on the end of a chisel driven into the vents of the rotor had no luck. I showered it with Blaster and the next morning it literally fell off the hub with a light tap of the hammer. It made me a believer!

 

[NH-Rob]

a farm mechanic once told me that if he drilled the bolt and then migged a nut to it filling in the drilled out portion and the nut with weld it would be much stronger and usually come out. Me i hate to drill so i just weld the nut to the bolt but if it was truely that stuborn i might try it.
Rob