• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

Broken Header Bolt

  • Thread starter Thread starter jboge123
  • Start date Start date
J

jboge123

Guest
Well I done did it now.

The PO left 3 broken header bolts in my 550L. I soaked the bolts in liqui wrench and then got to work with my EZ out extractor.

The extractor broke in the bolt. Does anyone have any tricks on how to remove these? Luckily, there is still some thread sticking out for me to grab on to.

IMG-1107.jpg
 
Sorry for the trouble. And no disrespect, but there is tons of info here on how to avoid breaking those bolts and what to do when they do break. Now that you got an ez-out busted that limits your options to EDM or trying to weld something onto the nub. Good luck
 
attachment.php


Maybe, just maybe you could use a dremel to carefully cut the bolt away from the easy out. This would probably leave the remaining bolt cut flush with the head though. At least you could possibly grab the easy out with vice grips and wiggle it out. Then your only option to deal with the bolt would be to drill and tap it out. To drill straight and perfectly centered then becomes the challenge, and your tap may damage some aluminum. A jig or guide of some sort to prevent the bit from going off center would help.

I managed to drill one and tap it out, weld a nut on another and unscrew it, and cut a slot in the last one and back it out. Three broken bolts and three removed in different ways. Unfortunately, the spark plug repair on that head was botched before I got it making it useless. Had I realized that to begin with I wouldn't have wasted so much time on three broken bolts.
 
+1 for the welder. Place a nut over the stub and weld it to the inside of the nut.

As well as the nut giving you something to wrench on, the heat from the welding helps to free up the stuck thread.
 
Thanks for all the advice! I will post when I get the chance to work on it again.

I've spent the past week fixing up a Cub Cadet, not quite as fun as a motorcycle :/
 
Had the same problem, same bike (1982) last month only I broke two of them. I took a dremel, finished off the end real flat and clean, tapped the center of the stud with a regular punch to mark the center and drilled it out with an electric hand drill using a small, then medium and then near full size of the diameter of the stud keeping the drill centered as I progressed. Once I got that far I took a tap from my Harbor Freight cheapy set and worked a new set of threads into the hole. I had to continuously back the tap out and clean and oil it but it worked great. No need to weld anything if you so not have access to a welder. Just take your time, it is easier than I had thought it would be. I had an easyout stuck and broken off too ... it popped out once I started to drill. They're useless for studs I found.
 
You must log in or register to reply here.
Back
Top