Broken bolt removal

[Toolhorder]

Had a real PITA one today. V6 Honda engine and when removing the 3 bolts that go through the side mount bracket/waterpump and into the block one didn't want to come easy. Tried the forward/reverse a couple turns to get it loose and then heat from a mini ductor machine and a little penetrate. After all the precautions it still snapped off. Removed the waterpump and t-belt and had 4-5 threads exposed outside the block. Tried locking pliers, knipex cobras, etc.. but no go. Tried heat again with the mini ductor and waxing the threads, and worked that awhile and still wouldn't go. Finally used a centering drill bit adapter and drilled it out. Tried the remover tool (made by Rigid) and it just slipped inside the hole. I then drilled it next size up and tried to break it with a chisel and it finally collapsed a bit onto itself and I was about to remove it with vice grips. I think I had almost 3 hours into this POS.

Anyone have any better suggestions?

 

[Buckaroo5]

I think you tried all the things I would have done. I have had this happen a number of times (it goes with working on old cars). Each time, I tell myself that I am going to be a lot more careful next time and not wrench on these bolts so hard. Penetrating oil, heat (i use a propane torch), a few whacks and some back and forth to avoid snapping it. And repeat. For me, it generally comes down to being in a hurry and getting impatient.

But - you got it out. Chalk it up to a learning experience.

P.S. Also, depending on the situation, I am more inclined these days to use a little anti-seize when re-assembling....but that's for next time.......

 

[fourjeepin]

Welder has always worked for me. Welding a nut to the stub gives you something to grip and the heat from the welder helps break it loose. Once or twice I have had to weld it on a second time. YMMV as I don't live in the rust belt. Amazing how quickly a vehicle rots there.

 

[Hammell]

x2 on welding a nut on it. Saved my bacon many times.

 

[ironmutt]

x3 on welder but put a washer just bigger than bolt and then nut works real nice if bolt is going in to aluminium

 

[heepr]

My order of attack is usually vise grips (if there is enough exposed thread), then left handed drill bits, then bolt extractors, then weld a nut to it.

I like that order because vise grips are easy and sometimes work. Welding almost always works but if it doesn't, hand drilling through the weld on the bolt center is next to impossible. I am also sometimes pleasantly surprised by the left handed bits.

 

[greasemonkey44]

sometimes smacking on the bolt head with a hammer can break up bimetal galling