Broken Bolt

[natesimpson74]

I had posted about this earlier, but now it is more extreme. While taking off my exhaust I broke a bolt. The rear pipe, stud closest to block. I tried extracting every way I know of possible. Nothing worked. Broke 4 different types of extractors. So I cut the stud down and started drilling. I got about 1/16" in and it won't drill anymore. I bought new cobalt drill bits, but they still won't cut through. What can I do??? I really want my bike to work again!!

[Goldsmith]

I liked what Tony did by squaring the end of the stud. I would try that.

[jdt3]

It sounds like you hardend the bolt by getting it to hot while you where drilling into it .Go to a machine shop and ask them what bit to use thy might have a bit that can handel a hardend bolt . If you can get a hole in to the bolt to get an easy out into it make sure the stud is a left or right hand thread and get the proper easy out for what ever thread you have. once you have done this try to heat the stud and then cool it off with wd 40 the contraction when it cools might help break it loose if that does not work try to back it out while it is hot just keep wrking it until you get it you might have to dril it completely out and put a healycoil back in but I would make that my last resort Good luck and I hope this helps.I feel your pain man Ive been in these situations before

[mscales]

So, what is left of the stud? Anything sticking out or are you flush to the head? Got a pic of the area?

[natesimpson74]

Now I am at a really bad spot. I got it to drill out a little ways. Someone at work said that a carbide bit would do- the job so I started with a carbide bit. Of course why would that work out, it broke off. So Now I have a carbide burr broken off flush with the head. WOW!! I don't know how much worse this can get!! Any ideas what to do now?

[mscales]

Again, is any of the stud sticking out? It is hard to help without all the information. Post a picture if you can.

[jdt3]

Take a small chisel grab a corner of the bit and knock it the oppisite way the bit was rotateing and start again . Go slow take your time and you will get it . Like mscales says to you need to post a pic so we can look at it . Dont force the drill let the the tool do the work when you get the broken bit out and keep it cool and lubricated with some heavy oil. Good Luck

[Goldsmith]

Not to be a party pooper but I vote for takeing it to somebody. Sounds like it's about to get expensive. Plus, who needs that stress.

[natesimpson74]

I have the stud drilled about 1/4" into the head, that is where I hit the extractor and it wont drill through it. That is when I used the carbide burr. The burr is flush with the head. I will bring my chisels home from work tomorrow and try to get that out. I really hope that it works because carbide burrs are about impossible to drill through. I would take a picture, but my camera is broken. I appreciate all the help.

[mscales]

On thing you can do if you have a die grinder or a Dremel tool. Usine a small cut off wheel cut a slot across the bolt and into the head flange. Then, using a square shanked screwdriver, tap tip into the slot you cut. Cut deepenough to get a good bit with the screwdriver and using a cresent wrench or tight fitting open end wrench and try to turn the stud out. The slot in the head will not hurt anything at all. IF you have one available to you use a impact hammer since these are made for for this type of purpose. The easyout is made from hardened tool steel and the carbide bit will chew up any more bits you use. Time to try something else.

[natesimpson74]

Well I fixed it!!! I brought it to a local machine shop and they welded a nut on the carbide burr and got that out. Then with a little messing around and a lot of drilling i got it drilled out and put a thread insert in. What a relief!! Thank you all very much for the help!!

[Goldsmith]

Hey Nate, thats great news! You are a loot braver than I to do all that. GOOD JOB!!