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Old 06-22-2010, 05:43 AM   #1
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Location: Florida
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I've had it happen twice and...

... was able to successfully remove the broken bolt by drilling it out.
I use successively larger LEFT-HAND drill bits.
Grainger has a nice set. They are expensive, though.
The trick is to start completely centered, so you'll need to carefully center-punch the broken bolt. You may need to file a flat spot if it's crooked.
Also, soak overnight with PB Blaster.
Once you start to see the threads, use a sharp pick and pick out the remnants.
Sometimes the action of the PB Blaster and the use of the left-handed bits will remove the broken bolt.
Happy Boxstering,
Pedro
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Old 06-22-2010, 09:27 AM   #2
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You will get it!

Had the same thing happen, my buddy and I tried it all...PB Blaster, heat and when after 7 hours he broke 3 easy outs(heavy duty aircraft one) I was worried. The next day he went at it again with an easy out and various bits until success. I bought a heli-coil kit from a local auto parts store used one insert and sold the kit on ebay to recoup my money (kit was 90.00). No problems since, and I coated the bolts with anti-seize on the way back in!
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Old 06-23-2010, 02:25 AM   #3
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Thanks all. Ended up buying a titanium pilot bit at Home Depot ($5.00), centered it, and using increasingly larger bits, removed the old bolt. Will have to use a helicoil though as the threads are now destroyed. Crazy that a 30 second job became an expensive 7 hour ordeal. Makes no sense.

Anyway, and as always, thanks for he suggestions and support.

Bradster
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