BROKEN BOLT

[6wheeler 669]

Well, I did it gentlemen. Broke off an exhaust flange bolt on a Kohler command 20, that i shoehorned into a JD 116 . And of course, that wasn't good enough. I drilled it, inserted my handy easy out. And, easily snapped it off too . I don't know what to do now. I can't drill it or, at least I don't know what to use. The blue flame penetrating solution I would usually use in this situation, won't work (aluminum head and all). Any Ideas? I heard that a masonary bit running slow might get it drilled, But, I have never tried it.. Thanks Pat

[Operator 7]

The easy out - out? How about a "backwards" drill bit, great $$ quality?

Just a little bit heat? Weld a nut to top? more than likely not huh?

Randy

[6wheeler 669]

All those thoughts ran thru my melon too Randy. Its broke off just below the surface. Dang it anyway(edited in case of younger viewers). I have to find something harder than the easyout to drill it. I was told a masonary bit is as hard as it gets. But, I don't know. I was also told to heat it up and cool it and heat it again to soften the easyout. But, as soon as I start the aluminum gets hot. Maybe a new head is in my future....

[TT-(Moderator) 1,162]

Three letters for you: E D M - which stands for Electro Discharge Machining.

The large machine shop where my father worked (as a tool room attendant) for many years had what they referred to as a "tap disintegrator".

Check this out --> http://www.metal-disintegrators.com/

You could try a plasma cutter (or water-jet machine?), but I'd say the best way to get that stud / broken extractor out of the aluminum head would be EDM.

Looks like you'll probably have to pull the head anyhow - and buy the appropriate gaskets and new bolts. (thanks a lot, Japanese Kohler ) So now all you have to do is either find someone who has one of those $$$$$$ machines - or find another cylinder head.

[puddlejumper 67]

I am just repeating something I read on another thread. But somebody said they removed a (hard out) with a dremel tool and the little carbide cutters available for them. Never tried it but he commented that it took hours but was successfull. :ychain:

[Operator 7]

Three letters for you: E D M - which stands for Electro Discharge Machining.

The large machine shop where my father worked (as a tool room attendant) for many years had what they referred to as a "tap disintegrator".

Check this out --> http://www.metal-disintegrators.com/

You could try a plasma cutter (or water-jet machine?), but I'd say the best way to get that stud / broken extractor out of the aluminum head would be EDM.

Looks like you'll probably have to pull the head anyhow - and buy the appropriate gaskets and new bolts. (thanks a lot, Japanese Kohler ) So now all you have to do is either find someone who has one of those $$$$$$ machines - or find another cylinder head.

It is amazing the things that can be learned about on Red Square!!

That is one amazing machine!

Pat I don't have one of those here.

New head

Randy

Thanks TT

[TT-(Moderator) 1,162]

A tungsten-carbide or diamond tipped drill bit would also get it out of there, but the stud is only 8MM (I believe) and trying to hold a hand drill solid and steady enough would be a challenge in itself.

[JimD 3,347]

Thanks for the idea TT. We have a wire EDM at work. I'll have to remember that in the future for all my broken stuff. :ychain:

[TT-(Moderator) 1,162]

The wire EDM process is a little different, Jim.

Burning out broken bolts, etc. would require a sacrificial electrode that doesn't pass through the workpiece. 25 years ago when I was machine shop student, the electrodes we used were made of machinable carbon. I have no idea what the composition of them would be in this modern age.

[6wheeler 669]

Thanks for your help Terry, I agree with what you said, I took the head off. I did enough damage myself trying different things. I think if I am going to drill it ,a drill press is going to be a must. We have a welding guy fairly close to me and, I think he does some machining too. So, I am going to run it up there and see if he can get it out. Thanks again. Pat

[Kelly 1,033]

I may have a head if you need one.

[sorekiwi 761]

One of the other guys at work broke an easy-out off in a bolt a couple of weeks ago. I thought it was going to be a major PITA and was thinking EDM, but one of our machinists just bored the thing out with a plain carbide endmilll (in the Bridgeport).

Cut through the easy out as easily as it cut through the broken bolt.

[sgtsampay 117]

Wow. I think that EDM thing is cool. Sure wish I knew about that a few month ago when i had 3 stuck bolts in an engine i was rebuilding,. i have to drill

them out with the drill press... Thats was PITA!

[buckrancher 2,694]

we have six edm machines at the company I work for and I'll use a

bridgeport mill and a good center cutting carbide endmill. to remove broken

bolts,studs etc.

our carbide endmills will cut thru easy-outs like a warm knife thru butter

We normaly use the edms on small size threads like 1/4-20 and smaller as 99%

of what we're burning out is a broken tap

Brian

( I can mill thru a cutting tap also with our endmills at 2500-4000rpm)

[Coadster32 793]

I'll use a bridgeport mill and a good center cutting carbide endmill. to remove broken bolts,studs etc.

I second that with my experience as well.