F*CK!!! What would you do? Advise?

[Rusker]

Removing the bolt it snapped in half. Used some vise grips to back the rest out and this is the result. Happened awhile back but I need to do something about it now. As you can see I don't have much to work with.

Drill it out, and re tap it?

[Ca_laurier]

use an extractor. can get them at any tool store

[Rusker]

Do they make one that handles hardware this small? How effective are they?

[Ca_laurier]

i snapped a mounting bolt for a oil pick up this week. used the one my boss has and bam was out in like 5 min

[slower than you]

Punch the center of it as a guide and try and drill it out with a small reverse drive drill bit. if you drill through it go bigger. i just did this on my exhaust manifold last week. it will spin right out with some luck. hope that helps.

[blueshark123]

yea they sell easy out taps that small to take it out i had to use it on my oil pan.

[downshift_sideways]

Try going to your local hardware store and purchasing some "Easy outs" or some "Extractors"

OR IF YOU HAVE A WELDER..

Take an ordinary nut, one that's I.D. more-or-less matches the OD of the broken stud. Take your mig-welder, and set it to a high-voltage setting (I use 5). Hold the nut in your hand (don't worry, you can let go as soon as it's tacked... if you hold on too long, you'll melt your fuckin hand). Okay you've got it tacked. Now. Lay a brutal weld into it. Just fill the damn thing up with metal. Try to avoid any air-gaps... get it good and hot. The whole nut should be glowing.

Give it time to cool. Now simply un-thread the bolt you just made...Easy!


OR

step one:
you will be drilling the bolt out completely, along with the original threads. You need to determine what size the stud is, and drill it out one incriment higher than that.

so... go to the hardware store, and get some brass pipe. You want the kind with a tapered outside thread on both ends. Length doesn't really matter, get one that's a few inches long so you've got something to work with.

okay, so now you've got your brass pipe, and you've got your oversized drilled manifold stud-hole. Take a tapered-pipe-tap and tap the oversized hole the same size as the brass pipe you bought. Okay, now thread the brass pipe in NICE and hard. (the length will come into play here... you'll be turning it in with a pair of channel locks or vise-grips)

With the brass pipe threaded into the hole, take a hacksaw or a cutoff wheel and cut the pipe as close as you can to the head. Then take an abrasive-pad on your pneumatic die-grinder and grind the brass until it's ABSOLUTELY flush.

Sweet. now you've got a fresh hole with no threads. Tap the hole the correct size for your stock turbo stud, and thread it on in. BAM. done.

BTW, you are using brass rather than tapping into the aluminum because brass, like steel, has greater clamping force with smaller threads(larger number/per inch). Unlike aluminum which has greater clamping force with larger threads (smaller number/per inch)

[Turtle]

This man knows what he speaks of... Try this!

[ame]http://youtube.com/watch?v=8Asb4RWMvig[/ame]

Originally Posted by downshift_sideways

Try going to your local hardware store and purchasing some "Easy outs" or some "Extractors"

OR IF YOU HAVE A WELDER..

Take an ordinary nut, one that's I.D. more-or-less matches the OD of the broken stud. Take your mig-welder, and set it to a high-voltage setting (I use 5). Hold the nut in your hand (don't worry, you can let go as soon as it's tacked... if you hold on too long, you'll melt your fuckin hand). Okay you've got it tacked. Now. Lay a brutal weld into it. Just fill the damn thing up with metal. Try to avoid any air-gaps... get it good and hot. The whole nut should be glowing.

Give it time to cool. Now simply un-thread the bolt you just made...Easy!

[SCato]

an Easy Out would get that out quick, try a tool store. you never know when you need them, but when you do they are amazing.

[CoSsilly]

if the turbos aluminum welt a bolt to it...
easyest way

[opponheimer]

Originally Posted by CoSsilly

if the turbos aluminum welt a bolt to it...
easyest way

lol............................ msglngth

[rps13sr20det]

Tons of different ways to do it....They have already been mentioned

[kikit-sideways]

if u are drilling and using an extractor, make sure that the hole is straight and lined up in the center, makes things alot easier so u dont mess up the threads, same thing happened to me, worked like a champ

[KA-T_240]

take off the housing machine it and just use a coupler.

[cotbu]

Tape over the compressor outlet, Get a punch, PB blaster, mallet(R) and a drill, Punch the center, the drill away about a mm or less. Get the flat head screwdriver place it over the bolt tap the screwdriver a couple of times to cut a groove in the bolt, unscrew with screwdriver.

drill bit should be smaller than the bolt

[240XTC]

^^^ down shift came up with a pretty ingenious way...nice!..but if you have no welder or your not too confident in the work that you might do on ur own, take it to the machine shop....it'll b about 10 bucks...i had mine taken off of my KA block (exhaust side)

[LA_phantom_240]

Use a drill bit that is slightly smaller than the bolt diameter. Then, you can use an extractor or a left handed drill bit to get it out no problem.

[MA JasonG]

Although extractor tools are easy to use, I've seen some people screw this up multiple times. If you feel uncomfortable using one and think you might mess up the threads just take it to a machine shop.

[SHIFT_*grind*]

Originally Posted by MA JasonG

Although extractor tools are easy to use, I've seen some people screw this up multiple times. If you feel uncomfortable using one and think you might mess up the threads just take it to a machine shop.

Exactly. You can go ahead and try to drill it out, but be careful. Make sure you drill the pilot hole dead center, and don't break the damn drill bit, or extractor, off in the bolt.

Because if you can't get it out yourself and you have to take it to a machine shop, it'll cost a lot more if they have to work around a broken drill bit. Don't ask how I know.

[300hp owen]

drill it out as on-center as possible with a small drillbit, then work your way to larger drillbits one after the other, being patient and using cutting oil to keep them from breaking.

after you reach the right size drillbit you will have removed all of the bolt except for the bolts-threads that are left in the hole.

these can then be removed as one long spring-like piece of spiral steel stuff and usually will come right out easily from all of the heat generated during the drilling process.

no re-tapping required as long as you stayed on center with your drilling!
even if you have wiped out some of the threads from going off center, you will still be fine to not re-tap the hole if its an application like that where you are just looking for clamping force and the seal is made with a gasket and not the threads.

good luck.

[Ian]

Originally Posted by 300hp owen

drill it out as on-center as possible with a small drillbit, then work your way to larger drillbits one after the other, being patient and using cutting oil to keep them from breaking.

after you reach the right size drillbit you will have removed all of the bolt except for the bolts-threads that are left in the hole.

these can then be removed as one long spring-like piece of spiral steel stuff and usually will come right out easily from all of the heat generated during the drilling process.

no re-tapping required as long as you stayed on center with your drilling!
even if you have wiped out some of the threads from going off center, you will still be fine to not re-tap the hole if its an application like that where you are just looking for clamping force and the seal is made with a gasket and not the threads.

good luck.

That's way hard and time consuming though. Honestly, do you think if he had to ask this question, he has the tools/skills to make that happen?


Easy-out/extractor is one good idea


or just take it somewhere to get it removed, that'd be what I would do in this situation just because the headache of messing up way outweighs the cost to have someone do it

[Rusker]

Originally Posted by Ian

he has the tools/skills to make that happen?

It is true that I don't have some of the tools mentioned, but I do have the skills to get it out. I just figured someone here might have had the same problem at one time and figured I'd ask for a few ideas. I must thank everyone for the overwhelming amount of ideas.

We have a few wire fed mig welders here at work that I've done random stuff on for my cars in the past. I think I'll try welding a nut on whats left and see if that works.

Thanks guys. I'll update the thread with what worked encase anyone has the same problem in the future.

[shmiddy]

+1 with the welding. its way better that drilling or anything like that. have a welder weld a nother peice of metal to it and screw it off. happened to me with my turbo outlet

[300hp owen]

how fucking hard is it to drill a goddamn hole in a piece of metal. wtf its not like my suggestion was requiring some major mechanical skills or seriously weird tools.

hand drill.
drill bits.
done.

how does it get any easier than that?