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How to Drill Out a Broken Bolt?
I over-torqued four bolts in the lower unit of an outboard, and the
heads of three bolts broke off. I managed to remove one of the broken bolt using a Dremel tool and a diamond grind bit. But I cannot remove the other two broken bolts using the Dremel tool. Based on the past posts in this newsgroup, I learn that the best option in this situation is to drill out the broken bolts. I would like to learn the details of the way to drill out the broken bolts. My question is: Which size of drill bit do I need? Should it be as large as the hole where the broken bolt is? Related questions: The bolts are for securing the water pump housing for the impeller. The hole for the bolt is at the edge of the water pump base -- meaning that one side of the hole is kind of thin -- something like 3/32" thick. The bolt itself is like 1/4" or slightly larger. Because I have over-torqued the bolts, I found that the holes pretty much losed most of the thread. If I drill out the bolts, I probably will find that the holes will become even larger. If I re-thread the hole after drilling out the bolts, I am afraid that the holes will be even larger. I am afraid that there will not be enough metal left. Is my estimation correct? I am wondering whether I may be better off somehow pouring in new metal into the holes and drill new holes instead of rethreading/enlarging the existing holes? The other thing is that there is supposed to have a gasket on top of the surface. I am wondering if I rethread and enlarge the holes, there may not be enough metal at the edge of the water pump base to bite into the gasket and prevent water from getting into the bolt. Is this something that I need to worry about? Thanks in advance for any info. Jay Chan |
How to Drill Out a Broken Bolt?
wrote in message
ups.com... I over-torqued four bolts in the lower unit of an outboard, and the heads of three bolts broke off. I managed to remove one of the broken bolt using a Dremel tool and a diamond grind bit. But I cannot remove the other two broken bolts using the Dremel tool. Based on the past posts in this newsgroup, I learn that the best option in this situation is to drill out the broken bolts. I would like to learn the details of the way to drill out the broken bolts. My question is: Which size of drill bit do I need? Should it be as large as the hole where the broken bolt is? Call around to hardware stores and ask if they sell spiral screw extractors. Before you jump in the car, measure the diameter of the bolt shafts you need to remove. And, if you know the socket size that fits the heads, write that down too. |
How to Drill Out a Broken Bolt?
If he's worried about how much metal is left then helicoils are
probably out of the question. The most important thing is to try very hard to drill down the center of the remaining bolt. It helps to grind the top flat and center punch before drilling. The surrounding metal in this case is far softer than the bolt so getting off center will be a big problem. Sometimes it is hard to use easy outs on smaller bolts because they tend to spread the bolt material out further jaming it in the hole. Sometimes I've been able to find a metric size that is slightly bigger than the american size and tap the hole to the metric size successfully. This is usually closer than the next size up america size. It is pretty hard to get anything into the hole to replace missing metal since I'm thinking you are working with cast aluminum. If it gets that bad then maybe securing threaded studs into the holes with epoxy might be worth a try. Particularly if there is some thread left. Then use nuts to secure the water pump. David Scheidt wrote: wrote: :I over-torqued four bolts in the lower unit of an outboard, and the :heads of three bolts broke off. I managed to remove one of the broken :bolt using a Dremel tool and a diamond grind bit. But I cannot remove :the other two broken bolts using the Dremel tool. Based on the past :posts in this newsgroup, I learn that the best option in this situation :is to drill out the broken bolts. I would like to learn the details of :the way to drill out the broken bolts. My question is: :Which size of drill bit do I need? Should it be as large as the hole :where the broken bolt is? The best way to do this is to get a selection of left-handed drill bits. These have the twist going the opposite way from a normal twist drill. You have to run your drill in reverse to drill a hole with one of these. That means, in addition to puting a hole in the bolt, you apply some anti-clockwise force to the bolt, which may back it out. Start with a small bit; drill exactly in the center, exactly perpendicular to the hole. Then move up to a bigger bit, and repeat. Increase the size of the bit until you're using a bit the size of the minor diamter of the bolt (the diameter of the round part of the bolt, minus the threads.). Then you can use a pick to pick the threads from the bolt out of the threads in the hole. You could also drill a hole, and try an EZ-out. There's a better description he http://www.dimebank.com/tech/BrokenBolt.html :Related questions: : The bolts are for securing the water pump housing for the :impeller. The hole for the bolt is at the edge of the water pump base :-- meaning that one side of the hole is kind of thin -- something like :3/32" thick. The bolt itself is like 1/4" or slightly larger. Because :I have over-torqued the bolts, I found that the holes pretty much losed :most of the thread. If I drill out the bolts, I probably will find :that the holes will become even larger. If I re-thread the hole after :drilling out the bolts, I am afraid that the holes will be even larger. : I am afraid that there will not be enough metal left. Is my :estimation correct? I am wondering whether I may be better off somehow :pouring in new metal into the holes and drill new holes instead of :rethreading/enlarging the existing holes? There are thread inserts, called heli-coils (that's the brand name of the original, and best, there are others), that may solve this problem for you. The hole needs to be drilled oversize, roughly to the major diamter of the hold hole, and then it's tapped for the insert. The insert is a coild of wire that allows the use of the original sized fastener. David |
How to Drill Out a Broken Bolt?
I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? -W wrote in message ups.com... I over-torqued four bolts in the lower unit of an outboard, and the heads of three bolts broke off. I managed to remove one of the broken bolt using a Dremel tool and a diamond grind bit. But I cannot remove the other two broken bolts using the Dremel tool. Based on the past posts in this newsgroup, I learn that the best option in this situation is to drill out the broken bolts. I would like to learn the details of the way to drill out the broken bolts. My question is: Which size of drill bit do I need? Should it be as large as the hole where the broken bolt is? Related questions: The bolts are for securing the water pump housing for the impeller. The hole for the bolt is at the edge of the water pump base -- meaning that one side of the hole is kind of thin -- something like 3/32" thick. The bolt itself is like 1/4" or slightly larger. Because I have over-torqued the bolts, I found that the holes pretty much losed most of the thread. If I drill out the bolts, I probably will find that the holes will become even larger. If I re-thread the hole after drilling out the bolts, I am afraid that the holes will be even larger. I am afraid that there will not be enough metal left. Is my estimation correct? I am wondering whether I may be better off somehow pouring in new metal into the holes and drill new holes instead of rethreading/enlarging the existing holes? The other thing is that there is supposed to have a gasket on top of the surface. I am wondering if I rethread and enlarge the holes, there may not be enough metal at the edge of the water pump base to bite into the gasket and prevent water from getting into the bolt. Is this something that I need to worry about? Thanks in advance for any info. Jay Chan |
How to Drill Out a Broken Bolt?
"Clams Canino" wrote in message link.net... I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? -W He broke the first two ... first. Eisboch |
How to Drill Out a Broken Bolt?
"Clams Canino" wrote in message link.net... I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? -W I was wondering the same thing. ;-) |
How to Drill Out a Broken Bolt?
"Eisboch" wrote in message ... "Clams Canino" wrote in message link.net... I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? -W He broke the first two ... first. Eisboch I know this because it's something I would do . Kibosh |
How to Drill Out a Broken Bolt?
"Clams Canino" wrote
I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Not to jump on the jump-on-Jay bandwagon (he's got enough trouble with his broken bolts already), but wasn't he the guy who asked what the difference is between foot pounds and inch pounds a while back? |
How to Drill Out a Broken Bolt?
Ernest Scribbler wrote: "Clams Canino" wrote I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Not to jump on the jump-on-Jay bandwagon (he's got enough trouble with his broken bolts already), but wasn't he the guy who asked what the difference is between foot pounds and inch pounds a while back? Good Lord, give him credit for trying to do his own work. So he makes expensive mistakes, I bet he learns from them. I have managed to break 5 drill bits in rapid succession. Now, If I remember, there are special tools for removing broken bits or taps. I suggest he look into a tool catalogue such as McMaster-Carr or MSC. |
How to Drill Out a Broken Bolt?
Frogwatch wrote: Ernest Scribbler wrote: "Clams Canino" wrote I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Not to jump on the jump-on-Jay bandwagon (he's got enough trouble with his broken bolts already), but wasn't he the guy who asked what the difference is between foot pounds and inch pounds a while back? Good Lord, give him credit for trying to do his own work. So he makes expensive mistakes, I bet he learns from them. I have managed to break 5 drill bits in rapid succession. Now, If I remember, there are special tools for removing broken bits or taps. I suggest he look into a tool catalogue such as McMaster-Carr or MSC. I have several tiny hardened end mills from MSC. They are no wider than a screwdriver blade and cost about $20 each and I have used them for such tasks to get down into a bolt hole (using the dremel tool) to make a screwdriver slot. You can also use the tiny diamond burr with th dremel to make a "dent" atop the broken bolt for the drill bit to start on when you drill it out. |
How to Drill Out a Broken Bolt?
"Ernest Scribbler" wrote in message
... "Clams Canino" wrote I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Not to jump on the jump-on-Jay bandwagon (he's got enough trouble with his broken bolts already), but wasn't he the guy who asked what the difference is between foot pounds and inch pounds a while back? Yes. Excellent question. However, I also agree with Frogwatch. You just have to develop a feel for how much force things are able to take, and where the gotchas are hiding. Try telling a 17 year old "With some screws, you want to gently turn them in backwards until you feel or hear a click, or you'll strip the threads". Mine said "Well, how do you know which screws?" I really couldn't tell him, except to say that the higher the price of the thing you're trying to fix, the more likely it is that you'll have a problem. :-) |
How to Drill Out a Broken Bolt?
"JoeSpareBedroom" wrote in message ... "Ernest Scribbler" wrote in message ... "Clams Canino" wrote I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Not to jump on the jump-on-Jay bandwagon (he's got enough trouble with his broken bolts already), but wasn't he the guy who asked what the difference is between foot pounds and inch pounds a while back? Yes. Excellent question. However, I also agree with Frogwatch. You just have to develop a feel for how much force things are able to take, and where the gotchas are hiding. Try telling a 17 year old "With some screws, you want to gently turn them in backwards until you feel or hear a click, or you'll strip the threads". Mine said "Well, how do you know which screws?" I really couldn't tell him, except to say that the higher the price of the thing you're trying to fix, the more likely it is that you'll have a problem. :-) True story. In high school autoshop, yes we used to have those, the grounds keepers for the sports field had their tractor in and were replacing a muffler. The gardener asked how tight to make the nuts. Someone in the class yelled out, "run it down until you hear a crack and then back of a 1/2 turn.". Everybody in the shop heard the crack as the U clamp broke. Class went in to hysterics. |
How to Drill Out a Broken Bolt?
"Frogwatch" wrote in message Good Lord, give him credit for trying to do his own work. So he makes expensive mistakes, I bet he learns from them. I have managed to break 5 drill bits in rapid succession. Not bolts...... I broke a head bolt on a Honda 50 when I was 12..... not TWO head bolts. -W |
How to Drill Out a Broken Bolt?
Clams Canino wrote:
"Frogwatch" wrote in message Good Lord, give him credit for trying to do his own work. So he makes expensive mistakes, I bet he learns from them. I have managed to break 5 drill bits in rapid succession. Not bolts...... I broke a head bolt on a Honda 50 when I was 12..... not TWO head bolts. -W I hate to say this, but from the questions Jay was asking in other threads, it was obvious this would be the results. Since Jay likes to do some of the basic work himself, he needs to find a shade tree mechanic who will help him with some basics, such as telling the difference between foot/lbs and inch/lbs. As long as he is doing "on the job training" and is using rec.boats as his tutor, he will continue to have problems. |
How to Drill Out a Broken Bolt?
"Reginald P. Smithers III" wrote in message
... Clams Canino wrote: "Frogwatch" wrote in message Good Lord, give him credit for trying to do his own work. So he makes expensive mistakes, I bet he learns from them. I have managed to break 5 drill bits in rapid succession. Not bolts...... I broke a head bolt on a Honda 50 when I was 12..... not TWO head bolts. -W I hate to say this, but from the questions Jay was asking in other threads, it was obvious this would be the results. Since Jay likes to do some of the basic work himself, he needs to find a shade tree mechanic who will help him with some basics, such as telling the difference between foot/lbs and inch/lbs. As long as he is doing "on the job training" and is using rec.boats as his tutor, he will continue to have problems. I wonder if he's using tools too large for certain jobs. I mean, sometimes you just look at a bolt and you know if you use an extra large ratchet handle (breaker bar??) as a substitute for more muscle, it's going to cause problems. Or, you can't access a bolt at the correct angle and end up stripping the head. My car mechanic actually likes having certain customers hanging out nearby so when he's bitching about a stuck or inaccessible bolt, he's got someone to complain to. This is where I learned that it often makes sense to remove "thing #1" in order to get a better angle for removing "thing #2", even if the manual says you shouldn't have to touch thing #1. More coffee.... |
How to Drill Out a Broken Bolt?
There is no substitute for practice.
JoeSpareBedroom wrote: "Reginald P. Smithers III" wrote in message ... Clams Canino wrote: "Frogwatch" wrote in message Good Lord, give him credit for trying to do his own work. So he makes expensive mistakes, I bet he learns from them. I have managed to break 5 drill bits in rapid succession. Not bolts...... I broke a head bolt on a Honda 50 when I was 12..... not TWO head bolts. -W I hate to say this, but from the questions Jay was asking in other threads, it was obvious this would be the results. Since Jay likes to do some of the basic work himself, he needs to find a shade tree mechanic who will help him with some basics, such as telling the difference between foot/lbs and inch/lbs. As long as he is doing "on the job training" and is using rec.boats as his tutor, he will continue to have problems. I wonder if he's using tools too large for certain jobs. I mean, sometimes you just look at a bolt and you know if you use an extra large ratchet handle (breaker bar??) as a substitute for more muscle, it's going to cause problems. Or, you can't access a bolt at the correct angle and end up stripping the head. My car mechanic actually likes having certain customers hanging out nearby so when he's bitching about a stuck or inaccessible bolt, he's got someone to complain to. This is where I learned that it often makes sense to remove "thing #1" in order to get a better angle for removing "thing #2", even if the manual says you shouldn't have to touch thing #1. More coffee.... |
How to Drill Out a Broken Bolt?
On Thu, 26 Oct 2006 04:35:50 GMT, "Calif Bill"
wrote: "JoeSpareBedroom" wrote in message ... "Ernest Scribbler" wrote in message ... "Clams Canino" wrote I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Not to jump on the jump-on-Jay bandwagon (he's got enough trouble with his broken bolts already), but wasn't he the guy who asked what the difference is between foot pounds and inch pounds a while back? Yes. Excellent question. However, I also agree with Frogwatch. You just have to develop a feel for how much force things are able to take, and where the gotchas are hiding. Try telling a 17 year old "With some screws, you want to gently turn them in backwards until you feel or hear a click, or you'll strip the threads". Mine said "Well, how do you know which screws?" I really couldn't tell him, except to say that the higher the price of the thing you're trying to fix, the more likely it is that you'll have a problem. :-) True story. In high school autoshop, yes we used to have those, the grounds keepers for the sports field had their tractor in and were replacing a muffler. The gardener asked how tight to make the nuts. Someone in the class yelled out, "run it down until you hear a crack and then back of a 1/2 turn.". Everybody in the shop heard the crack as the U clamp broke. Class went in to hysterics. Now *that* was funny!! |
How to Drill Out a Broken Bolt?
Gene Kearns wrote:
snip... This is a *BIG* hot button for me, but this is endemic of no longer teaching real Industrial Arts in our public schools. Higher education, from mechanic programs, to engineering programs, to medical programs all suffer from incoming students that have, in too many cases, never even held a tool in their hands..... and in almost all cases, save some rural areas, lack any real experience in using tools or in dealing with the logic required of fixing everyday items that need repair or adjustment..... -- You got that right! When my two sons were in jr high, they had to take homemaking courses half the year and shop the other half. The pc crowd decided that the girls whould have equal time hammering, cutting etc. while the boys learned baking, etc. I don't mind if the girls want to take shop, but don't force the boys to be Suzy Homemaker unless they want to. |
How to Drill Out a Broken Bolt?
"Don White" wrote in message
... Gene Kearns wrote: snip... This is a *BIG* hot button for me, but this is endemic of no longer teaching real Industrial Arts in our public schools. Higher education, from mechanic programs, to engineering programs, to medical programs all suffer from incoming students that have, in too many cases, never even held a tool in their hands..... and in almost all cases, save some rural areas, lack any real experience in using tools or in dealing with the logic required of fixing everyday items that need repair or adjustment..... -- You got that right! When my two sons were in jr high, they had to take homemaking courses half the year and shop the other half. The pc crowd decided that the girls whould have equal time hammering, cutting etc. while the boys learned baking, etc. There are few things more pathetic than a man who cannot project power in the kitchen, especially if he's over the age of maybe 25. If the homemaking courses were formulated by Emeril Lagasse, I'd be impressed. |
How to Drill Out a Broken Bolt?
JoeSpareBedroom wrote:
wrote in message ups.com... I over-torqued four bolts in the lower unit of an outboard, and the heads of three bolts broke off. I managed to remove one of the broken bolt using a Dremel tool and a diamond grind bit. But I cannot remove the other two broken bolts using the Dremel tool. Based on the past posts in this newsgroup, I learn that the best option in this situation is to drill out the broken bolts. I would like to learn the details of the way to drill out the broken bolts. My question is: Which size of drill bit do I need? Should it be as large as the hole where the broken bolt is? Call around to hardware stores and ask if they sell spiral screw extractors. Before you jump in the car, measure the diameter of the bolt shafts you need to remove. And, if you know the socket size that fits the heads, write that down too. I tried that already. Either it didn't work or I went too easy on the hammer. Anyway, it could not grab the bolt and could not spin the bolt out. I attempted to drill one of the broken bolt away. But this simply messed up the thread in one of the hole. Finally, a copy of the Mercury Service Manual arrived last night. I read it and realized that the water pump base could be removed just by removing 6 bolts, and each broken bolt went through a threaded hole in the water pump base into another threaded hole in the lower unit. Seem like the threaded holes in the water pump base had some chemical reaction with the bolts, and the threads in the hole in the water pump base had completely corroded away (the thread on the bolt mating with the threaded hole in the water pump base was also corroded away significantly and that was part of the reason why the bolt head broken off easily before the thread got damaged by being over-torqued). In other words, the water pump base was not holding on the broken bolt, and only thing that was holding on with the broken bolt is the threaded hole in the lower unit, and I can remove the water pump base easily. After I had removed the water pump base, I could see a large section of the broken bolt sticking out in the open, and I easily removed them using a channellock plier. Is this a happy ending? Not really. In the attempt of drilling out one of the broken bolt, I ended up messing up the thread in one of the hole in the lower unit (the other three are fine). I don't know what is the best way to deal with this. I will bring the lower unit to a marine mechanic in this afternoon to see if he can help. The other thing is that I can simply replace the water pump base and the broken bolts, and this should take care of the corroded threaded holes in the water pump base. But I am wondering why the holes and the bolts can get so corroded. The bolts must be stainless steel, right? I didn't know that stainless steel bolts can react to casted alumimum lower unit. How should I prevent this problem from happening again? Any idea? Thanks. Jay Chan |
How to Drill Out a Broken Bolt?
wrote in message
ups.com... JoeSpareBedroom wrote: wrote in message ups.com... I over-torqued four bolts in the lower unit of an outboard, and the heads of three bolts broke off. I managed to remove one of the broken bolt using a Dremel tool and a diamond grind bit. But I cannot remove the other two broken bolts using the Dremel tool. Based on the past posts in this newsgroup, I learn that the best option in this situation is to drill out the broken bolts. I would like to learn the details of the way to drill out the broken bolts. My question is: Which size of drill bit do I need? Should it be as large as the hole where the broken bolt is? Call around to hardware stores and ask if they sell spiral screw extractors. Before you jump in the car, measure the diameter of the bolt shafts you need to remove. And, if you know the socket size that fits the heads, write that down too. I tried that already. Either it didn't work or I went too easy on the hammer. Anyway, it could not grab the bolt and could not spin the bolt out. I attempted to drill one of the broken bolt away. But this simply messed up the thread in one of the hole. Hammer???????? |
How to Drill Out a Broken Bolt?
David Scheidt wrote:
wrote: :I over-torqued four bolts in the lower unit of an outboard, and the :heads of three bolts broke off. I managed to remove one of the broken :bolt using a Dremel tool and a diamond grind bit. But I cannot remove :the other two broken bolts using the Dremel tool. Based on the past :posts in this newsgroup, I learn that the best option in this situation :is to drill out the broken bolts. I would like to learn the details of :the way to drill out the broken bolts. My question is: :Which size of drill bit do I need? Should it be as large as the hole :where the broken bolt is? The best way to do this is to get a selection of left-handed drill bits. These have the twist going the opposite way from a normal twist drill. You have to run your drill in reverse to drill a hole with one of these. That means, in addition to puting a hole in the bolt, you apply some anti-clockwise force to the bolt, which may back it out. Start with a small bit; drill exactly in the center, exactly perpendicular to the hole. Then move up to a bigger bit, and repeat. Increase the size of the bit until you're using a bit the size of the minor diamter of the bolt (the diameter of the round part of the bolt, minus the threads.). Then you can use a pick to pick the threads from the bolt out of the threads in the hole. You could also drill a hole, and try an EZ-out. There's a better description he http://www.dimebank.com/tech/BrokenBolt.html :Related questions: : The bolts are for securing the water pump housing for the :impeller. The hole for the bolt is at the edge of the water pump base :-- meaning that one side of the hole is kind of thin -- something like :3/32" thick. The bolt itself is like 1/4" or slightly larger. Because :I have over-torqued the bolts, I found that the holes pretty much losed :most of the thread. If I drill out the bolts, I probably will find :that the holes will become even larger. If I re-thread the hole after :drilling out the bolts, I am afraid that the holes will be even larger. : I am afraid that there will not be enough metal left. Is my :estimation correct? I am wondering whether I may be better off somehow :pouring in new metal into the holes and drill new holes instead of :rethreading/enlarging the existing holes? There are thread inserts, called heli-coils (that's the brand name of the original, and best, there are others), that may solve this problem for you. The hole needs to be drilled oversize, roughly to the major diamter of the hold hole, and then it's tapped for the insert. The insert is a coild of wire that allows the use of the original sized fastener. David As mentioned in my other reply, I have removed the broken bolts by simply removing the water pump base. And I also attempted to drill out the broken bolt; but I could not get the drill bit to center on the bolt because the bolt was sunk inside the hole and I could not see the surface of the bolt that well. This ended up messing up the thread of the hole. Hopefully, the heli-coils will fix this problem. Thanks. Anyway, I will bring the lower unit to a marine mechanic later in this afternoon, and I will see how he will fix the thread in the hole. Jay Chan |
How to Drill Out a Broken Bolt?
Which size of drill bit do I need?
I can't really answer this question without knowing the sizes of the bolts. For example, the ideal sizes for a 1/4-20 thread would be a #7 drill. Different thread and different sizes would require different drill sizes. Should it be as large as the hole where the broken bolt is? Yes, BUT it means the size of drill that will fit in the hole where there are good threads. Thanks for the tip of selecting the right kind of drill bit. Although I didn't need to drill the bolts out because I got them off by removing the water pump base, I may find your tip comes in handy if I get another case of broken bolts. Somebody with expertise in this area needs to physically examine what you have. It is really impossible to give quality advice without seeing the exact problem(s). Yes, indeed. And this is the reason why I will bring the lower unit to a marine mechanic to have it fixed (to fix a threaded hole that I messed up). Jay Chan |
How to Drill Out a Broken Bolt?
Clams Canino wrote:
I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Actually, I could have broken all four -- instead of merely three. I must have come to my sense when I was bearing down on the 4th bolt. I have a tendency to over-doing anything (such as running my knee to the point that I needed to have a surgery done on my knee). And tightening up the bolts too much is one of my tendency. That was the reason why I bought a torque wrench hoping that using the torque wrench will prevent me from over-torquing the bolts. Unfortunately, I mistook 60-inch-pounds with 60-feet-pounds, and I ended up over-torquing the bolts by 12 times. And the fact that the torque wrench that I use is quite big (designed more for higher torque such as for torquing the propeller); therefore, I didn't get a good feel of the tension. I have ordered a 1/4" torque wrench that is designed for lower torque (such as 60-inch-pounds); hopefully, this will prevent me from making a similar mistake. Jay Chan |
How to Drill Out a Broken Bolt?
wrote in message
ps.com... Clams Canino wrote: I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Actually, I could have broken all four -- instead of merely three. I must have come to my sense when I was bearing down on the 4th bolt. I have a tendency to over-doing anything (such as running my knee to the point that I needed to have a surgery done on my knee). And tightening up the bolts too much is one of my tendency. That was the reason why I bought a torque wrench hoping that using the torque wrench will prevent me from over-torquing the bolts. Unfortunately, I mistook 60-inch-pounds with 60-feet-pounds, and I ended up over-torquing the bolts by 12 times. And the fact that the torque wrench that I use is quite big (designed more for higher torque such as for torquing the propeller); therefore, I didn't get a good feel of the tension. I have ordered a 1/4" torque wrench that is designed for lower torque (such as 60-inch-pounds); hopefully, this will prevent me from making a similar mistake. Jay Chan 1/4" for 60 ft lbs.....hang on a minute. Who makes a 1/4" drive wrench with 60 *FOOT* lbs in its range? |
How to Drill Out a Broken Bolt?
Frogwatch wrote:
Frogwatch wrote: Ernest Scribbler wrote: "Clams Canino" wrote I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Not to jump on the jump-on-Jay bandwagon (he's got enough trouble with his broken bolts already), but wasn't he the guy who asked what the difference is between foot pounds and inch pounds a while back? Good Lord, give him credit for trying to do his own work. So he makes expensive mistakes, I bet he learns from them. I have managed to break 5 drill bits in rapid succession. Now, If I remember, there are special tools for removing broken bits or taps. I suggest he look into a tool catalogue such as McMaster-Carr or MSC. I have several tiny hardened end mills from MSC. They are no wider than a screwdriver blade and cost about $20 each and I have used them for such tasks to get down into a bolt hole (using the dremel tool) to make a screwdriver slot. You can also use the tiny diamond burr with th dremel to make a "dent" atop the broken bolt for the drill bit to start on when you drill it out. Yes, I used the Dremel tool with a diamond grind bit to form a slot on top of one of the broken bolt, and I used a screw driver to remove that bolt -- successfully. But this didn't work for another two bolts that were sunk inside the holes. The pointy grinding bit simply could not have a good angle of attack on the bolt surface. What ended up happening was that the two ends of the slot were slightly lower than the center of the slot and this weakened the slot. When I used the screw driver to turn the bolt, I ended up stripping the slot. But this is kind of behind me now. As mentioned in my another reply, I found an easy way to remove the broken bolts by simply removing the water pump base, and this allowed the broken bolts to show up in the open, and I used a channellock piler to remove the broken bolts. Nice to talk with you. Jay Chan |
How to Drill Out a Broken Bolt?
wrote in message ps.com... Clams Canino wrote: I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Actually, I could have broken all four -- instead of merely three. I must have come to my sense when I was bearing down on the 4th bolt. I have a tendency to over-doing anything (such as running my knee to the point that I needed to have a surgery done on my knee). And tightening up the bolts too much is one of my tendency. That was the reason why I bought a torque wrench hoping that using the torque wrench will prevent me from over-torquing the bolts. Unfortunately, I mistook 60-inch-pounds with 60-feet-pounds, and I ended up over-torquing the bolts by 12 times. And the fact that the torque wrench that I use is quite big (designed more for higher torque such as for torquing the propeller); therefore, I didn't get a good feel of the tension. I have ordered a 1/4" torque wrench that is designed for lower torque (such as 60-inch-pounds); hopefully, this will prevent me from making a similar mistake. Jay Chan Look at the bright side. You are going to have a very well stocked tool box by the time you are finished with this project. :-) Eisboch |
How to Drill Out a Broken Bolt?
"Don White" wrote in message ... Gene Kearns wrote: snip... This is a *BIG* hot button for me, but this is endemic of no longer teaching real Industrial Arts in our public schools. Higher education, from mechanic programs, to engineering programs, to medical programs all suffer from incoming students that have, in too many cases, never even held a tool in their hands..... and in almost all cases, save some rural areas, lack any real experience in using tools or in dealing with the logic required of fixing everyday items that need repair or adjustment..... -- You got that right! When my two sons were in jr high, they had to take homemaking courses half the year and shop the other half. The pc crowd decided that the girls whould have equal time hammering, cutting etc. while the boys learned baking, etc. I don't mind if the girls want to take shop, but don't force the boys to be Suzy Homemaker unless they want to. So you figure the women will be the kitchen slave. Not much more pathetic than a guy who has to go to Burger King because he can not cook anything! |
How to Drill Out a Broken Bolt?
Call around to hardware stores and ask if they sell spiral screw
extractors. Before you jump in the car, measure the diameter of the bolt shafts you need to remove. And, if you know the socket size that fits the heads, write that down too. I tried that already. Either it didn't work or I went too easy on the hammer. Anyway, it could not grab the bolt and could not spin the bolt out. I attempted to drill one of the broken bolt away. But this simply messed up the thread in one of the hole. Hammer???????? Do you mean I am not supposed to use a hammer to work with the screw extractor? I am under the impression that I am supposed to drill a hole in the middle of the borken bolt, and hammer the screw extractor down into the hole, and then use some kind of handle bar to lock on the screw extractor and turn counter clockwise, and hopefully the screw will back out. This was exactly what the owner of the hardware store told me to do. May be we are talking about two different types of screw extractors? May be you are referring to the type that is like a drill bit, and we are supposed to use it with a power drill (running in reverse) to dill and back off the bolt? I could not use that type because the bolt was sunken inside a small hole that the special drill bit was too large to fit inside. Jay Chan |
How to Drill Out a Broken Bolt?
Eisboch wrote:
wrote in message ps.com... Clams Canino wrote: I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Actually, I could have broken all four -- instead of merely three. I must have come to my sense when I was bearing down on the 4th bolt. I have a tendency to over-doing anything (such as running my knee to the point that I needed to have a surgery done on my knee). And tightening up the bolts too much is one of my tendency. That was the reason why I bought a torque wrench hoping that using the torque wrench will prevent me from over-torquing the bolts. Unfortunately, I mistook 60-inch-pounds with 60-feet-pounds, and I ended up over-torquing the bolts by 12 times. And the fact that the torque wrench that I use is quite big (designed more for higher torque such as for torquing the propeller); therefore, I didn't get a good feel of the tension. I have ordered a 1/4" torque wrench that is designed for lower torque (such as 60-inch-pounds); hopefully, this will prevent me from making a similar mistake. Jay Chan Look at the bright side. You are going to have a very well stocked tool box by the time you are finished with this project. :-) Eisboch yes, but will he know how to use any of them. |
How to Drill Out a Broken Bolt?
wrote in message ps.com... Clams Canino wrote: I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Actually, I could have broken all four -- instead of merely three. I must have come to my sense when I was bearing down on the 4th bolt. I have a tendency to over-doing anything (such as running my knee to the point that I needed to have a surgery done on my knee). And tightening up the bolts too much is one of my tendency. That was the reason why I bought a torque wrench hoping that using the torque wrench will prevent me from over-torquing the bolts. Unfortunately, I mistook 60-inch-pounds with 60-feet-pounds, and I ended up over-torquing the bolts by 12 times. And the fact that the torque wrench that I use is quite big (designed more for higher torque such as for torquing the propeller); therefore, I didn't get a good feel of the tension. I have ordered a 1/4" torque wrench that is designed for lower torque (such as 60-inch-pounds); hopefully, this will prevent me from making a similar mistake. Jay Chan Buy a hammer impact tool. And then make sure the socket you use does not bottom on the case. That way you get twisting and an impact lengthwise at the same time. Was the only thing that got aluminum screws out of a Kawasaki engine case with out stripping the heads. |
How to Drill Out a Broken Bolt?
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How to Drill Out a Broken Bolt?
wrote in message
ps.com... Call around to hardware stores and ask if they sell spiral screw extractors. Before you jump in the car, measure the diameter of the bolt shafts you need to remove. And, if you know the socket size that fits the heads, write that down too. I tried that already. Either it didn't work or I went too easy on the hammer. Anyway, it could not grab the bolt and could not spin the bolt out. I attempted to drill one of the broken bolt away. But this simply messed up the thread in one of the hole. Hammer???????? Do you mean I am not supposed to use a hammer to work with the screw extractor? I am under the impression that I am supposed to drill a hole in the middle of the borken bolt, and hammer the screw extractor down into the hole, and then use some kind of handle bar to lock on the screw extractor and turn counter clockwise, and hopefully the screw will back out. This was exactly what the owner of the hardware store told me to do. May be we are talking about two different types of screw extractors? May be you are referring to the type that is like a drill bit, and we are supposed to use it with a power drill (running in reverse) to dill and back off the bolt? I could not use that type because the bolt was sunken inside a small hole that the special drill bit was too large to fit inside. Jay Chan This is the type I was talking about. No hammer is used. The flutes of the tool are deep enough that they grip without having to be forced into place. http://www.mytoolstore.com/hanson/extractr.html |
How to Drill Out a Broken Bolt?
"Calif Bill" wrote in message
. net... "Don White" wrote in message ... Gene Kearns wrote: snip... This is a *BIG* hot button for me, but this is endemic of no longer teaching real Industrial Arts in our public schools. Higher education, from mechanic programs, to engineering programs, to medical programs all suffer from incoming students that have, in too many cases, never even held a tool in their hands..... and in almost all cases, save some rural areas, lack any real experience in using tools or in dealing with the logic required of fixing everyday items that need repair or adjustment..... -- You got that right! When my two sons were in jr high, they had to take homemaking courses half the year and shop the other half. The pc crowd decided that the girls whould have equal time hammering, cutting etc. while the boys learned baking, etc. I don't mind if the girls want to take shop, but don't force the boys to be Suzy Homemaker unless they want to. So you figure the women will be the kitchen slave. Not much more pathetic than a guy who has to go to Burger King because he can not cook anything! Even dumber: Guys in college who didn't know how to operate a washing machine. |
How to Drill Out a Broken Bolt?
JoeSpareBedroom wrote: "Calif Bill" wrote in message . net... "Don White" wrote in message ... Gene Kearns wrote: snip... This is a *BIG* hot button for me, but this is endemic of no longer teaching real Industrial Arts in our public schools. Higher education, from mechanic programs, to engineering programs, to medical programs all suffer from incoming students that have, in too many cases, never even held a tool in their hands..... and in almost all cases, save some rural areas, lack any real experience in using tools or in dealing with the logic required of fixing everyday items that need repair or adjustment..... -- You got that right! When my two sons were in jr high, they had to take homemaking courses half the year and shop the other half. The pc crowd decided that the girls whould have equal time hammering, cutting etc. while the boys learned baking, etc. I don't mind if the girls want to take shop, but don't force the boys to be Suzy Homemaker unless they want to. So you figure the women will be the kitchen slave. Not much more pathetic than a guy who has to go to Burger King because he can not cook anything! Even dumber: Guys in college who didn't know how to operate a washing machine. Stainless steel DOES react with aluminum but I am not sure what to do about it. There is a material you can buy at marine stores to separate ss parts from Aluminum but am not sure if this is used on bolts. |
How to Drill Out a Broken Bolt?
Calif Bill wrote:
"Don White" wrote in message ... Gene Kearns wrote: snip... This is a *BIG* hot button for me, but this is endemic of no longer teaching real Industrial Arts in our public schools. Higher education, from mechanic programs, to engineering programs, to medical programs all suffer from incoming students that have, in too many cases, never even held a tool in their hands..... and in almost all cases, save some rural areas, lack any real experience in using tools or in dealing with the logic required of fixing everyday items that need repair or adjustment..... -- You got that right! When my two sons were in jr high, they had to take homemaking courses half the year and shop the other half. The pc crowd decided that the girls whould have equal time hammering, cutting etc. while the boys learned baking, etc. I don't mind if the girls want to take shop, but don't force the boys to be Suzy Homemaker unless they want to. So you figure the women will be the kitchen slave. Not much more pathetic than a guy who has to go to Burger King because he can not cook anything! No kitchen slave... just don't think our kids should be girliemen , like that California crowd. |
How to Drill Out a Broken Bolt?
Reginald P. Smithers III wrote:
Eisboch wrote: wrote in message ps.com... Clams Canino wrote: I wanna know how you broke *three*. I mean - after you broke one... didn't a clue rake at least try to hit you over the head about the rest of them? Actually, I could have broken all four -- instead of merely three. I must have come to my sense when I was bearing down on the 4th bolt. I have a tendency to over-doing anything (such as running my knee to the point that I needed to have a surgery done on my knee). And tightening up the bolts too much is one of my tendency. That was the reason why I bought a torque wrench hoping that using the torque wrench will prevent me from over-torquing the bolts. Unfortunately, I mistook 60-inch-pounds with 60-feet-pounds, and I ended up over-torquing the bolts by 12 times. And the fact that the torque wrench that I use is quite big (designed more for higher torque such as for torquing the propeller); therefore, I didn't get a good feel of the tension. I have ordered a 1/4" torque wrench that is designed for lower torque (such as 60-inch-pounds); hopefully, this will prevent me from making a similar mistake. Jay Chan Look at the bright side. You are going to have a very well stocked tool box by the time you are finished with this project. :-) Eisboch yes, but will he know how to use any of them. Wonder where he lives? Maybe he'd loan out those tools on occasion. |
How to Drill Out a Broken Bolt?
"Frogwatch" wrote in message ps.com... JoeSpareBedroom wrote: "Calif Bill" wrote in message . net... "Don White" wrote in message ... Gene Kearns wrote: snip... This is a *BIG* hot button for me, but this is endemic of no longer teaching real Industrial Arts in our public schools. Higher education, from mechanic programs, to engineering programs, to medical programs all suffer from incoming students that have, in too many cases, never even held a tool in their hands..... and in almost all cases, save some rural areas, lack any real experience in using tools or in dealing with the logic required of fixing everyday items that need repair or adjustment..... -- You got that right! When my two sons were in jr high, they had to take homemaking courses half the year and shop the other half. The pc crowd decided that the girls whould have equal time hammering, cutting etc. while the boys learned baking, etc. I don't mind if the girls want to take shop, but don't force the boys to be Suzy Homemaker unless they want to. So you figure the women will be the kitchen slave. Not much more pathetic than a guy who has to go to Burger King because he can not cook anything! Even dumber: Guys in college who didn't know how to operate a washing machine. Stainless steel DOES react with aluminum but I am not sure what to do about it. There is a material you can buy at marine stores to separate ss parts from Aluminum but am not sure if this is used on bolts. It is called anti-seize. And the best for aluminum is Nevr-seize. |
How to Drill Out a Broken Bolt?
"Don White" wrote in message ... Calif Bill wrote: "Don White" wrote in message ... Gene Kearns wrote: snip... This is a *BIG* hot button for me, but this is endemic of no longer teaching real Industrial Arts in our public schools. Higher education, from mechanic programs, to engineering programs, to medical programs all suffer from incoming students that have, in too many cases, never even held a tool in their hands..... and in almost all cases, save some rural areas, lack any real experience in using tools or in dealing with the logic required of fixing everyday items that need repair or adjustment..... -- You got that right! When my two sons were in jr high, they had to take homemaking courses half the year and shop the other half. The pc crowd decided that the girls whould have equal time hammering, cutting etc. while the boys learned baking, etc. I don't mind if the girls want to take shop, but don't force the boys to be Suzy Homemaker unless they want to. So you figure the women will be the kitchen slave. Not much more pathetic than a guy who has to go to Burger King because he can not cook anything! No kitchen slave... just don't think our kids should be girliemen , like that California crowd. And how is he to be a manly man, when he can not man the BBQ? |
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