Help on a bolt

[Sheck]

Hey guys, i was re-building the brakes yesterday and once i finished with that i noticed my turbo to manifold bolts were loose. So i proceded to tighten them up next thing you know i managed to brake one of the bolts in the manifold a few mm down. Ok annoyed so i pulled all the surrounding stuff off and moved the turbo out the way, then i drilled a hole throught the bolt and proceded to use and ezy-out to remove the offending bolt.
The ezyout snapped!!
And now i cant drill through the ezy out cause its high tensile, is there any special drill bits i can buy or better yet is there a shop on the south side of brissy that will remove the offending bolt for me??

Thanks for any help!
Dave

PS the hole i drilled was off center (due to unevenness of broken bolt surface) so i cant go up in size unless i want to re-tap the hole off center which will prolly not fit through the turbo.

[manga_blue]

Sheck, in Melbourne there are a few guys that specialise in mobile thread repairs. They bring their van to you. You might try asking around at outlets like Repco, etc, if they know of any up there.

[OMY005]

Hello Dave, Is the bolt in the head, manifold or turbo housing? I have some carbide drills at work which should be able to drill it out. What size is the thread so I can see if I have a suitable size? Do you have a picture of where it is stuck?

Andrew.

[Sheck]

Hey andrew, the bolt is in the exhaust manifold (Greddy type), i just bought a carbide drill and have been drilling for about 30min non stop and it has gone in maybe .5-1mm.

The guys at trade tools didnt suggest anyone that could help only said that i'd have a lot of fun with it

I'll get back to drilling and stop for lunch and to check on this thread again.

Thanks!
Dave

[OMY005]

OK, Is it a through or blind hole? If a through hole go from the other side it broke in. The drilling forces want to unwind the thread. If all this fails you mightl have to have it burnt out with a EDM machine. Let us know how you go.

Andrew.

[mr_rotary]

I don't have the catalogue in front of me right now however do a search on Snapon for the tool you require:

http://www.snapontools.com.au

[Sheck]

its a blind thread
i might just take it off the road for a couple of months a build a new minifold for it if i cant get it out by today.

what would this tool be called? i'll have a look through the site and see if i can find something helpful.

Cheers!!
Dave

[bigdog]

From another forum:

\"Better you than me pal! Those things can be quite the pain.

Use a small center punch to break the EZ out up, not only are they hard but they are brittle too and will bust up easily with a properly ground punch. You can also use a dental burr on a dremel tool to hollow them out, then break them up.

When you have the EZ Out busted and out of there, take a 3/16 drill bit and drill all the way through the frigging bolt, then follow up with a 1/4\" bit until the head of the bolt comes off. Remember to use oil when drilling this stuff, but I'm sure you're familiar with proper technique.

If you can do this in a drill press, that would be my recommendation.

Anyway, once the head is drilled off the bolt and you have a 3/16 hole in it, use a punch or a nail set to collapse the wall of the drilled out bolt, then push it into the hole. Hopefully the tube is open so you can shake it outta there.\"

[bigdog]

and from further reading... it seems that a dremel with small conical stone at high speed and very light pressure will eat the easyout away. Too much pressure will destroy the stone quickly, so be patient.

[OMY005]

i might just take it off the road for a couple of months a build a new minifold for it if i cant get it out by today.

That seems a bit extreme.

I can drop by on my way home from work today if you like and have a look. I have removed many broken bolts, studs & taps in the past.

Andrew.

[Sheck]

wow cool , thats a good idea! might give it a shot cause it beats drilling for the next few days!

went to the snapon site and found a couple of cool extraction tools but nothing that'd help me drill through faster.

Cheers guys!!

[Sheck]

Andrew, i want to make the new manifold anyways so i can move the turbo down lower. This would let me make a better exhaust system, pretty much straight line out the back.

Thanks heaps for that offer!! I'll have to take you up on that, just gimmie a call on my mobile when you finish work and i'll give you my addy if i havent got it out yet. PMed you with my details.

Cheeers!
Dave

[Sheck]

Didnt want to hit it with a hammer for fear of the manifold cracking. Dads gonna take it to work and get one of the guys there to have a go at it with their special tools.

Thanks for your help everyone!!
Dave