Seized/broken/damaged Bolt Extraction

Date: Thu, 22 Feb 1996 11:13:06 -0500
From: Motorheadx@aol.com
Subject: Broken bolts

Good morning, Broken bolts, studs and bleeder screws are challenging and it helps to observe Burns' Law: If it's hard, you're doing it wrong. (The exception proves the rule). Although each situation of snappage may be different in terms of materials, access and available tools, there are some guidelines.

1. Avoid snappage by using heat, penetrants and proper application of tools. Take the time to set up so you can avoid the problem. This is especially helpful on exhaust manifold studs where snappage is otherwise likely. Get to know the beauty of proper torque. Replace studs before they break. Use proper quality bolts of suitable grades and avoid cheap fasteners. How annoying to retorque a cylinder head and have the last stud snap off flush at the block. There's never enough time to do it right but there's always enough time to do it over.

2. Snappage may have stretched the metal and caused the threads to dig in. If you break a drill bit or extraction tool your lot in life will be unhappily increased. Try the slow but steady method of drilling carefully in incremental diameters until the wall of the item is thin enough to collapse with a punch or a chisel. Your pleasant sense of achievement will nearly obscure the anxiety felt when the metal let go. For bleeder screws: Get thee to a vice and use successive drilling. Do not introduce metal into the hydraulic bore.

3. If you are faced with removing a broken bit or extraction tool begin by taking a break and thinking about it. Next try drilling 4 small holes beside it and continue this trend until it can be freed. Yes, this does demand skill and patience. You may need to install a helicoil. Resolve to avoid future pain.

Have fun,
Jeff and your friends at Motorhead
2811-B Old Lee Hwy Fairfax, VA 22031 (800) 527-3140
Home of daily drivers

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