need help with broken stud extractor

[proboscis]

Hi all, I was trying to remove a broken bolt with a craftsman 3-piece "deck-out screw and bolt remover" -

https://www.amazon.com/Craftsman-Deck-Out-Screw-Removers-9-52151/dp/B00MU8GDA6

and broke the tip off, now I have half the bolt and tip stuck inside the hole. I've tried a titanium drill bit and a dremel grinder bit, nothing seems to work. I figure the tip is hardened steel, any ideas what to use? Thanks

 

[plinker]

If the bolt is not too deep where it's broke off, you can likely weld a nut to it to get it out.

 

[2ndGearRubber]

Carbide burr may be able to erode it. What's it stuck in, and how much access?

 

[EOC_Jason]

Yep, probably welding something to it to extract it is going to be your best bet.

Otherwise you'll need to find a friend with a mill or a machine shop and they can drill it all out with a carbide bit.

 

[Wamsutta]

You remove that the same way you remove broken taps. You break it up into pieces using a center punch. Don't be surprised if you ruin a center punch in the process. Might be a good idea to have several punches ready.

 

[tatra]

Safety glasse at minimum and preferably a shield . Buddy would up at doctors with a piece buried in his cheek .

 

[joecon]

If there is room, you can take a spot weld cutter[ that is like a small hole saw]
and take the center out and use it to cut around the broken bit. The cutter will
center on the hardened part and follow it down.

 

[CJM8515]

https://www.dremel.com/en_US/products/-/show-product/accessories/9904-tungsten-carbide-cutter


Dremel carbide cutter

 

[BillK]

Depending on what it is you are working on and how portable it is, see if there is a local machine shop that has a tap disintegrator. That will make quick work of it and probably cost less that finding a grinding bit or carbide drill to drill it out.

 

[Ign]

....and once you resolve this lesson learned I hope: don't use traditional "EZ outs."

A left hand drill bit has a 99% greater chance of success

 

[R_einan]

Is the bold broken off flush or below flush? It is it proud of the surrounding surface? If it’s proud you have a ton of options, if it’s not, drilling it out may be your only option. Might try a cobalt bit, or a carbide cutter.

 

[proboscis]

It's flush, and there's plenty of room to work, it's on a motorcycle exhaust. Here's a pic

thanks all!

 

[BillK]

If you ae good with a Mig welder i would try to weld a nut on it and see what happens. If not it is going to be very hard to drill it out. If you can find someone with a disintegtrator it would be a quick job. Call a couple of automotive machine shops and see if they have one or know someone who does.

 

[trackwelder]

Get a washer that has a hole smaller than the threaded hole. Place the washer over the hole and Weld the hole closed and place a nut on the washer. Weld the nut to the washer filling the area inside the nut. Use a socket or wrench to turn the nut and remove the problem. It may take a few tries but I have never failed to remove a tap,extractor or bolt using this method.

 

[jonesg]

It's flush, and there's plenty of room to work, it's on a motorcycle exhaust. Here's a pic

thanks all!

Pic failed, if its a cast alum cyl don't use a punch or you risk snapping the boss. Either mig a nut or give it to a machine shop.
Perfect opportunity to buy a small mig welder.

 

[seagull369]

I've had decent success using Dremel-sized (1/8" shaft) solid carbide burrs purchased on ebay to grind out broken taps or extractors. Something like this: It takes a lot of time and patience, but it has worked. They're only ~$10 for a variety pack, when shipped from China, anyway. Get ones that are double cut and include "cylindrical end cut," which have cuts on the cross section as well and "ball" types (see pics). Those burr shapes will allow you to grind head-on. I think the pack I linked to includes both styles.

When using, let the bit do the work and don't use excessive force. If you don't, you'll wear down the burr fast and also bend the shafts, since they're usually only made of mild steel. Also, use cutting oil.

If you can find someone who has an metal disintegration machine (MDM), that will get everything out easy peasy.

 

[proboscis]

Thanks all! I will try the dremel carbide burr.

 

[Dust]

When a coworker broke off an EZ-Out in my truck doing exhaust studs, I bought a couple carbide drill bits off eBay and went to town. The Dremel bits didn't work worth a damn for me, but the carbide twist drill bit ate up the extractor in about five minutes with patient application.

 

[Legion Prime]

Don't forget chemical assistance. Hit it with Kroil, PB or something for a day or two, then hit it up with the big red wrench (if possible, if not a soldering gun can heat it up a bit) then immediately hit it with a candle. The wax will wick its way into the threads and help act as a lubricant. Then hit it with a center punch which will both shock the fastener and give you a starting point for a left handed drill bit. That's been my regime and it is only rarely I've ever had to proceed from there to an EZ out without then proceeding to drilling the whole thing out.

 

[Dingleburry]

Id prob just cut the boss off and weld a new one on...