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How to remove rusted 8mm bolt remnant? #4505799
09/02/17 08:37 PM
09/02/17 08:37 PM
Joined: Dec 2016
Posts: 2,161
VA
maverickfhs Offline OP
maverickfhs  Offline OP
Joined: Dec 2016
Posts: 2,161
VA
I am doing some maintenace on the motorcycle EXUP valve and sheared one of the rusted 8mm bolt.

https://www.tapatalk.com/groups/fazer1000/exup-valve-maintenance-t1524.html

I have drilled a hole inside it, but not sure how to remove it completely?

Any advice? Thanks


2006 Civic EX 202K/AT
2006 Acura TSX 180K/AT
Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs] #4505825
09/02/17 09:15 PM
09/02/17 09:15 PM
Joined: Aug 2014
Posts: 497
WA
SnowDrifter Offline
SnowDrifter  Offline
Joined: Aug 2014
Posts: 497
WA
Build it up with weld, weld a nut to it, turn it out


2005 Tahoe - 135k
2003 Forester(the swagger wagon) - Rehomed
1999 Passat - Rehomed
Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs] #4505827
09/02/17 09:23 PM
09/02/17 09:23 PM
Joined: Aug 2013
Posts: 2,529
Central Maryland
HangFire Offline
HangFire  Offline
Joined: Aug 2013
Posts: 2,529
Central Maryland
Try to remove all the head. It's the tension of the head against the surface that binds most screws in place.

After that, you can try the weld trick, or you can drive one of the many kinds of "EZ Out" tools into it. These are generally Left Hand Thread tapered, tempered screws that you spin counterclockwise, the idea is to bind in the whole and unscrew the drilled-out remains of the bolt.


Various musings: http://hangfire.net
Re: How to remove rusted 8mm bolt remnant? [Re: HangFire] #4505845
09/02/17 09:53 PM
09/02/17 09:53 PM
Joined: Oct 2012
Posts: 4,590
Taiwan
Ducked Offline
Ducked  Offline
Joined: Oct 2012
Posts: 4,590
Taiwan
Don't like the threaded EZ out things. They often don't grip, and if they do you risk breaking them off and then you've just armoured the fastner that you might have to drill out.

The fluted extractors that you hammer into a drilled hole have sometimes worked for me.

Drilling out with a reverse threaded bit is often recommended and makes sense, since you have to drill anyway, but I havn't been able to find those here.

Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs] #4505855
09/02/17 10:14 PM
09/02/17 10:14 PM
Joined: Jan 2007
Posts: 17,501
Clovis, CA
Merkava_4 Offline
Merkava_4  Offline
Joined: Jan 2007
Posts: 17,501
Clovis, CA
I'd use a Proto extractor.


Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs] #4505967
09/03/17 05:14 AM
09/03/17 05:14 AM
Joined: Jan 2013
Posts: 1,833
Texas
WyrTwister Offline
WyrTwister  Offline
Joined: Jan 2013
Posts: 1,833
Texas
I would give the remainder of the bolt a good squirt of PB Blaster . Maybe repeat at several intervals then try the square tool that is pictured in the previous quote .


Wyr
God bless
Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs] #4505978
09/03/17 05:46 AM
09/03/17 05:46 AM
Joined: Nov 2006
Posts: 19,893
MA, Mittelfranken.de
Trav Offline
Trav  Offline
Joined: Nov 2006
Posts: 19,893
MA, Mittelfranken.de
If its in aluminum and broke on removal you probably have zero chance with an extractor unless your very lucky. I use a very small left handed bit and get it dead straight then open the hole a drill size at a time until is almost all gone then pick the threads out with a hardened pick.
Don't drill too deep, use an old bolt to figure out how much is left in there and mark your drill bit. I had to do this on 8 manifold bolts, it came out perfect and I was able to use the original threads, we do it almost daily in the rust belt.
You could also drill it smooth if you buggered the drilling and use a helicoil.


ASE L1, Master. Deutsch Meisterbrief.
Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs] #4505986
09/03/17 06:06 AM
09/03/17 06:06 AM
Joined: Jul 2007
Posts: 4,195
Midwest USA
LoneRanger Offline
LoneRanger  Offline
Joined: Jul 2007
Posts: 4,195
Midwest USA
Seeing only the subj line, thought you'd found an old Mauser rifle ...



'09 Subaru Forester ...................(QS HM 5W30)
'16 Moto Guzzi Stelvio 1200 .....(ENI i-Ride PG 10W60)
Re: How to remove rusted 8mm bolt remnant? [Re: Ducked] #4506001
09/03/17 07:27 AM
09/03/17 07:27 AM
Joined: Dec 2016
Posts: 2,161
VA
maverickfhs Offline OP
maverickfhs  Offline OP
Joined: Dec 2016
Posts: 2,161
VA
Originally Posted By: Ducked
Don't like the threaded EZ out things. They often don't grip, and if they do you risk breaking them off and then you've just armoured the fastner that you might have to drill out.

The fluted extractors that you hammer into a drilled hole have sometimes worked for me.

Drilling out with a reverse threaded bit is often recommended and makes sense, since you have to drill anyway, but I havn't been able to find those here.


Likewise, I did break one left handed extractor one and it's still inside the drilled hole of the remnants of the bolt.


2006 Civic EX 202K/AT
2006 Acura TSX 180K/AT
Re: How to remove rusted 8mm bolt remnant? [Re: Trav] #4506004
09/03/17 07:31 AM
09/03/17 07:31 AM
Joined: Dec 2016
Posts: 2,161
VA
maverickfhs Offline OP
maverickfhs  Offline OP
Joined: Dec 2016
Posts: 2,161
VA
Originally Posted By: Trav
If its in aluminum and broke on removal you probably have zero chance with an extractor unless your very lucky. I use a very small left handed bit and get it dead straight then open the hole a drill size at a time until is almost all gone then pick the threads out with a hardened pick.
Don't drill too deep, use an old bolt to figure out how much is left in there and mark your drill bit. I had to do this on 8 manifold bolts, it came out perfect and I was able to use the original threads, we do it almost daily in the rust belt.
You could also drill it smooth if you buggered the drilling and use a helicoil.


Thanks Trav. I was able to drill a small hole and was able to go through on the other side, then used a left handed bit and now broke left handed bit inside it.

Also, what do you mean by hardened pick?Just regular pick? I'll use your trick and see if I have any luck.

Should I again start the drilling on it now?

I don't have access to a welder frown


2006 Civic EX 202K/AT
2006 Acura TSX 180K/AT
Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs] #4506083
09/03/17 09:32 AM
09/03/17 09:32 AM
Joined: Jan 2013
Posts: 1,833
Texas
WyrTwister Offline
WyrTwister  Offline
Joined: Jan 2013
Posts: 1,833
Texas
If you have a broken off pick in there , it will require a VERY GOOD bit to make any progress .

Perhaps if you can use a torch & heat it ul pat least red hot & let it cool as slowly as possible , you can take some of the hardness out ?

Might experement on the part of the extractor you broke off ?

Sounds like this will not be a fun / easy time .

I think some machine shops may have a device that uses a very strong arc / spark to " burn it our ?

https://www.google.com/search?q=electric...&channel=fs


Wyr
God bless
Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs] #4506253
09/03/17 12:29 PM
09/03/17 12:29 PM
Joined: Nov 2006
Posts: 19,893
MA, Mittelfranken.de
Trav Offline
Trav  Offline
Joined: Nov 2006
Posts: 19,893
MA, Mittelfranken.de
Originally Posted By: maverickfhs
Originally Posted By: Trav
If its in aluminum and broke on removal you probably have zero chance with an extractor unless your very lucky. I use a very small left handed bit and get it dead straight then open the hole a drill size at a time until is almost all gone then pick the threads out with a hardened pick.
Don't drill too deep, use an old bolt to figure out how much is left in there and mark your drill bit. I had to do this on 8 manifold bolts, it came out perfect and I was able to use the original threads, we do it almost daily in the rust belt.
You could also drill it smooth if you buggered the drilling and use a helicoil.


Thanks Trav. I was able to drill a small hole and was able to go through on the other side, then used a left handed bit and now broke left handed bit inside it.

Also, what do you mean by hardened pick?Just regular pick? I'll use your trick and see if I have any luck.

Should I again start the drilling on it now?

I don't have access to a welder frown


Good picks are hardened steel but some cheap ones will bend and not hardened. Craftsman has some decent ones but don't bother with HF ones or their bits.
So now you have a bit broken off in one and an extractor in the other?
The only bit that will go through both is a solid carbide bit but Jesus don't break that off in there or you will need an electron drill (AKA Elox or tap burner).
It sounds like you got a pretty deep hole dug so its time to stop digging and rethink the situation.


ASE L1, Master. Deutsch Meisterbrief.
Re: How to remove rusted 8mm bolt remnant? [Re: Trav] #4506374
09/03/17 03:27 PM
09/03/17 03:27 PM
Joined: Dec 2016
Posts: 2,161
VA
maverickfhs Offline OP
maverickfhs  Offline OP
Joined: Dec 2016
Posts: 2,161
VA
Not at all Trav, it's just one bolt and can make my life easy if I can extract it.

Let me explain and I would truly appreciate some help.

One of the bolt head sheared/snapped:



That's the size of it:



I was able to drill a hole through the remnant and then was using a left handed bit/bolt extractor of Harbor Freight, utizling open end wrench and that snapped inside it.


2006 Civic EX 202K/AT
2006 Acura TSX 180K/AT
Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs] #4506392
09/03/17 03:57 PM
09/03/17 03:57 PM
Joined: May 2012
Posts: 1,399
Georgia
AVB Offline
AVB  Offline
Joined: May 2012
Posts: 1,399
Georgia
Remove the rest of the bolts and take the cover off. You may be able to use a stud remover to get the rest out. If not you are going to need a good drill bit to drill out the hardened extractor.

Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs] #4506395
09/03/17 04:03 PM
09/03/17 04:03 PM
Joined: May 2012
Posts: 1,399
Georgia
AVB Offline
AVB  Offline
Joined: May 2012
Posts: 1,399
Georgia
It looks like a stud remover isn't going to work, that is one of the cover bolts not one of the bolts that hold the valve in. I would pull the valve out and either take it somewhere to get some help with a torch or put it in a vice and drill it on out.

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