How extract broken bolts?

[Mr.Nutcase]

What would be the best way to remove this broken bolt>
http://www.garagejournal.com/forum/showthread.php?p=2010740#post2010740
See post 3,

Pictures of the broken bolt

 

[sanddan]

I would try a left handed drill bit. They usually work better than the typical extractor like easyout (which isn't).

 

[frankt]

I can't really tell from the pict , how close to the surface it is broken off , but a little trick I have done several times is , select a nut same size as the broken bolt , set it on the head , centered exactly over the bolt , take a 1/16 welding rod with the proper amp setting , put the rod straight into the broken bolt and weld it to the nut { disconnect battery lead first , to protect the alternator and computer if it has one } if it breaks off the first attempt , try it again , allow it to cool for a few seconds , gently put a socket on the nut and rock it slightly , { loose to tight } it it is very free , just back it out , this requires a good steady welding hand , trust me it does work well , Frank

 

[blacK20]

I agree a mig is definitely the best way to get that out. But chances are if he's asking for help, then I have a feeling that he doesn't have a welder. In that case some left hand drills and a steady hand is your best bet.

 

[gloveman132]

From http://www.weldingtipsandtricks.com/bolt-or-stud-extraction-comments.html

"Put a nut over the broken bolt and place the mig gun on the nut, then while holding the nut down with the MIG nozzle, start welding. Fill the nut and when it cools, use a wrench to remove. I think it works so well because the heat and the current are flowing down thru the threads which breaks the rust etc."

 

[NUTTSGT]

Welding the nut on works decently.

 

[holdover]

if you do not have a welder I have had great luck using a torx bit, I drill a hole a bit undersize, drive the bit in and they usually come out. I also soak well with kroll before trying. The torx bit works so well I haven't used an easyout for years

 

[Mr.Nutcase]

The bolt is a m6x1.00
what left bit should I use?
http://buy1.snapon.com/catalog/tools.asp?tool=all&Group_ID=1266&store=snapon-store

 

[garfunkle24]

If you can get it perfectly centered and may need to use an extractor, use the biggest size under 6mm you can find. I usually use a 3/16 for an m6.

Also, check out my extractor thread here: http://www.garagejournal.com/forum/showthread.php?t=62687&highlight=Extractor&showall=1

 

[csargents1546]

http://http://www.qbaroo.com/quikcentercom/

Use this and an extractor like this

http://http://www.walmart.com/ip/Proto-Extractor-Sets-set-screw-extractor-10-p/15640523

 

[Jack Burton]

Over the years, I've tried a lot of things including welding on a new bolt, which works in the right situation (when you have room).

In your situation, I'd ***** punch the center of the stud, center punch, and then drill a hole about a 1/4" deep still leaving some decent meat around the circumference (you don't want the shaft to mushroom when you wack it). Then some penetrating oil.

1st: I'd try a tapered sheet metal reamer in the new hole, giving it a couple light blows while turning it counterclockwise.

2nd: I'd try a manual impact driver with a nice sharp phillips bit. These things are excellent.

3rd: I'd hold a propane torch on the stud for 2 minutes and wack it again with the manual impact.

I'm not a big fan of the lisle easy outs because most people end up having to hit them too hard, expanding the threads creating another problem.

Be patient and those sheared bolts will come free without a lot of $ and you won't have to **** around with helicoils.

 

[sberry]

Its a rare day I use an extractor, at time do drill them out, but 99% are welded.

 

[Mr.Nutcase]

I used a matco left hand drill bit, (set DMCL5)
It came out

 

[rlitman]

Its a rare day I use an extractor, at time do drill them out, but 99% are welded.

I've had pretty good luck with extractors, but they won't remove a broken tap, like in your picture. In those cases, I've actually been lucky enough to be able to burn out the tap entirely each time with an o/a welding tip. You set up an oxidizing flame, and put the heat right on the tap until it's getting yellow. Then slowly open up the oxygen, and watch it disappear in a shower of sparks.