Pelican IMS bearing stud has separated inside shaft

[2000boxster986]

Hopefully a reverse drill bit will work. I've even had luck with a dab of epoxy on a nail head and slowly backed a bolt out once. But, you're right, since it didn't go in and jam and just the sealant is holding it may help with it's removal. Hopefully it won't hinder it turning. Yes, take a pic I'm sure others have ideas as well. Good Luck! Once you're back on the road this will all be in the past....

[black_box]

So, bad got worse..... The plan was to drill into it a bit and then use a screw extractor to pull out the bolt shaft. While I went to the store to buy the appropriate extractor, the guy I have been working with drilled into the bolt. When I returned, he had drilled into it, and had chewed up the threads on the top side of the hole (see pic), making it impossible to use an extractor (should've done it myself I guess).

So, now the situation is that there is a 9mm (as measured) hole drilled into the case, with part of the old bolt still stuck inside. While it may still be possible to get the old bolt out, I don't want to take any chances of getting metal into the motor by drilling through, so I think creating a new, shallower threaded hole may be the way to go here. I am thinking that I will probably go ahead and try to clean up the hole to remove the first 9mm of old bolt, then tap the next larger diameter of metric threads into that. This job is becoming a nightmare.

[black_box]

this is the photo (it's actually the bottom r-hand hole)

[2000boxster986]

Ghezzz, it did go from bad to worse. Do you know anyone that is a machinist? Might be worth having someone who works with this stuff daily come over and take a look. Might even be worth putting the car on a flatbed and taking it to a machine shop or someone similar. Hate to go to that length but at this point it might be better than having to pull the engine and punch a new hole. Again, just a thought. I feel for you, been there done that on past car projects.