HELP! Removing snapped bolts from Aluminum...

[JK]

I snapped off 2 bolt in my nailhead timing chain cover removing the water pump. What's the best way you've found to get them out?

[FEDER]

I use a Heliarc. Build up a nipple on the end of the broken bolt then grab it with vise grips twist it back and forth and screw it out. Or the drill and easyout method.
Ive had better luck 1st way. ---FEDER

[Slide]

What feder said, but I'll add that I have had some success using a MIG. TIG is much better, though.

You can get a screw extractor (the "easy-out" feder mentioned) from your local SuperMega Home Improvement Warehouse Store(TM). These will usually do the job if you don't have access to a TIG welder.

One other thing: whenever you are dealing with threads that are aluminum or stainless, ALWAYS use anti-seize compound. PERIOD. If not, you are begging for galled threads. I have learned this one the hard way...several times! http://www.jalopyjournal.com/ubbthreads/images/graemlins/blush.gif http://www.jalopyjournal.com/ubbthreads/images/graemlins/mad.gif

[zman]

If you go with the easy-out method, be very careful about drilling into the bolt and keep it centered. Use a small pit to very carefully drill a pilot hole first. Take your time with it...

[UKAde]

in industry there are two other methods spark erosion is the main one the other is an acid which removes the steel and doesn't harm the alumiium
i have also tig welded items onto broken stud another method i have also used with some sucsess is to heat the item up and melt candle wax into the stud /hole then if there is enough left to turn it it quite often comes out
the melted wax is very thin and also acts as a lubricant to help release the thread

when it does come out i would recommend buying a helicoil kit to rethread the hole with a nice new strong steel thread

UKAde

[Unkl Ian]

If your going to try the EZ Out method,spend the couple bucks extra for a name brand set.
The "3 sets for a Dollar" brand will just create more problems,becuse you can't drill a broken EZ-out.


If it was mine,and I didn't have access to a welder,
I'd heat the area until the bolt was nice and hot,
then apply some oil or wax and let it cool completely.
Drill the bolt as big as practical,and use the EZ-out.

[scarliner]

If you use the easy out method, make sure you get the broken bolt surface as flat as possible and use a center punch, to make a starting location for your drill bit, I sometimes grind the end of the punch dia. to fit the hole size,if its broken off below the surface,make sure your as close to center as possible,start with a small drill and work your way up to the correct size hole for your easyout.If you do have to repair the threads, I have had real good luck with a product called-"keenserts",they are tougher and hold up better than a regular heli-coil.Plus you dont need a special size tap to use for the threads to retain it,they use standard thread sizes.Word of caution, they make heavy and light duty,inserts, make sure you get the correct one for your use.

[Flatdog]

Best way I found is to CAREFULLY drill bolt out to minor dia of bolt they run a tap to remove steel treads that were left in the alumium.

[Bruce Lancaster]

And study the top of the bolt carefully before making your center punch--figuring out the center is tricky, especially if you don't do this often, because the broken spiral means you are not looking at a circle. It is possible with care and luck to drill right out one step at a time until the threads are just barely visible all or most of the way around, then pick out the remnant with dental tools. Study the hole with good light at every pass so you know when you are reaching threads. If you are off a bit and break through on one side only, it's still usually possible to pick the remaining shell out--all the violence will have loosened it a bit by now.

[FuelFC]

Spray with Kroil or JB-80. Let soak while driving to Graingers for bits.
Step up in size with left handed drill bits if welder not available. Follow advice until you just get to minor diameter of thread size.

[banzaitoyota]

I also endorse the left handed bit method

[noboD]

All these are excellant ideas. I've also had success useing a Dremel and slotting the end of the screw, then use a good screwdriver. Of course , this is after soaking and tapping carefully to loosen.

[59BuickWagon]

Surprised no one has mentioned the "put a washer on and weld the stud to the washer and then weld a nut on the washer" method.