Help!! Stud Removal...

S

Sallad

New member
Ok, this is my first post here and I'm asking for some suggestions. Long story short I have managed to twist off the one and only bolt in on the exhaust flanges of my C90.... That would be the front top one for those unfamiliar. There is about an 1/8" sticking out still, I have already drilled through the stud. But... In my infinite wisdom I tried using an easy-out, these are evil little inventions that I do not think highly of anymore.... now I have an easy-out that won't come out and is broken off inside the bolt. Tried center punching it to try and drill and it flattend two of my center punches.:fight1: Anyways, now what? do I try and weld a nut to the stud? Unfortunatly I think that won't work, I'm fairly certain the threads in the cylindar are boogerd already, I think thats why the bolt wouldn't come out. When I initially started trying to remove it it started coming easy and got progressivly harder to turn, to the point that I was backing it out a 1/4 turn and in an 1/8 turn and so forth trying to ease it out. Didn't work, so this is where I'm at.... I'm more scared of permanantly damaging my cylinder than anything else. Any advise would be appreciated. Thankyou!
 
Sounds like you're going to have to drill that puppy out and either use a heliocoil to rethread it with a larger stud on the side that goes into the cylinder or have a machine shot rethread it. Personally I would choose the latter. Heliocoils are ok for bolts that don't require much torquing. Either way, I'd take it to a machine shop to get fixed. They could probably do in 10 minutes what would take you an hour and a half.
 
I would also recommend taking it to a machine shop.I have worked in a machine shop for twelve years now,we have a burning machine that removes broke off bolts screws etc...I have welded nuts on bolts and have even made a t handle and welded them to an object and removed them.You can drill the bolt out and use a sharp punch and slowly hammer away towards the center of the hole and if your lucky the remaining threads will break off and you can re-tap the hole.The machine I spoke of earlier burns a hole down the center of the bolt and then you take and chip away at the remaining threads on the bolt.Basically you can do the same with drilling the only problem here is you need a good starting hole for the drill,if the surface is flat or you can make it flat by grinding the bolt down,this would give you a good surface to use a center drill and then drill it to get a staright drill hole.

What is the size of the bolt?

If you have the cash take it to your local machine shop if not you can do it yourself if you just drill slow and make sure you drill it in the center you should be fine.But then again I have done this a lot and I have the tools.
I hope this has helped you a little If you lived close I would hook ya up and do it for you.Good Luck To You

Be sure and post the results.
Later
 
Well, sorry for the long wait but I eventually got it and didn't even have to go bigger on the bolt, the threads cleaned up nicely. Used a roto-zip with a few dimond tipped grinding stones:bluethum: Went through the easy-out and other drill bits I had broke off in the bolt like they were butter:plus1:. Back on the road now with no more leaks!!
 
um, yeah, so i guess you discovered that extractors are made of some extremely hard tough and brittle metal ;)

next time, use a proper tap handle on those things
 
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