Drilling out easy out

[itsnotanova]

This only works if the broken easyout is broken into steel bolt stuck into an item made of aluminum. I had it happen to me once and I took my mig welder to the broken bolt/easy out. You have to build a puddle high enough to where you can also weld it to a bolt. It took me about ten tries before everything came out. Because the piece I was working on was aluminum, the mig steel wire doesn't bond to the aluminum. I also didn't have the voltage high enough to melt the aluminum threads.

[DWBOX2000]

The bolt is 6mm or just over 1/8" in diameter. Easy out is about 1/8 at it's widest point but I did not get it in all the way. (probably why it broke) There is not much room around the easy out to drill out.

I am amazed that everyone is saying there is no bit hard enough to drill into the easy out. I put a dremmel on it yesterday and ground a nice hole dead center into the easy out. Maybe I just keep doing that until its gone. Since the easy out is not so deep, not much is in the bolt to grind out. Obviously desperate for a postive spin.


Thinking outside the box for you engineer types"
The bolt that broke holds on a bracket that holds the brake line to the Wheel Carrier. Is there any type of glue that I could just glue to the bracket to the carrier? I'm getting desperate now. Ideas?

[Xpit77]

Originally Posted by itsnotanova

This only works if the broken easyout is broken into steel bolt stuck into an item made of aluminum. I had it happen to me once and I took my mig welder to the broken bolt/easy out. You have to build a puddle high enough to where you can also weld it to a bolt. It took me about ten tries before everything came out. Because the piece I was working on was aluminum, the mig steel wire doesn't bond to the aluminum. I also didn't have the voltage high enough to melt the aluminum threads.

This works. Seen it done a few times. By a welder , a very good welder.

[Gelbster]

Originally Posted by Xpit77

This works. Seen it done a few times. By a welder , a very good welder.

So ,if we are going to buy a new $1000(??) Mig welder to remove a tiny easy out -just my kinda project ! :-).
For such precise welding on such a small Easy-Out wouldn't TIG be better ?
Either way , which machines do you recommend and why?
The common useage for this situation on the M96 would be the exhaust manifold bolts ?

[itsnotanova]

Originally Posted by Gelbster

So ,if we are going to buy a new $1000(??) Mig welder to remove a tiny easy out -just my kinda project ! :-).
For such precise welding on such a small Easy-Out wouldn't TIG be better ?
Either way , which machines do you recommend and why?
The common useage for this situation on the M96 would be the exhaust manifold bolts ?

I own a mig welder and build things or repair things with it all the time. My mig is my favorite tool. I wish I had a tig and knew how to use it too. I believe a tig would not be better for this process because it's a slower welding process and would heat up the surrounding aluminum metal too much. You'll need a quick hot weld that a mig will give you. DWBOX, you might know someone who has a mig welder? I get not wanting to do that and my second recommendation would be to drill & tap another hole like Steve had suggested.

[Xpit77]

Originally Posted by Gelbster

So ,if we are going to buy a new $1000(??) Mig welder to remove a tiny easy out -just my kinda project ! :-).
For such precise welding on such a small Easy-Out wouldn't TIG be better ?
Either way , which machines do you recommend and why?
The common useage for this situation on the M96 would be the exhaust manifold bolts ?

First I am not a welder.But i`ve seen it done but not in this exact application.

[Gelbster]

Originally Posted by Xpit77

First I am not a welder.But i`ve seen it done but not in this exact application.

For such a small bolt, Mig is too hot and clumsy.It is 1/8" diameter !!! If it was 1/4" maybe,1/2" certainly.
Tig would be a much wiser choice because it is far more precise and will cause much less localized heating.Lets see what Mr. Diablo says?