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#4505799 - 09/02/17 08:37 PM How to remove rusted 8mm bolt remnant?
maverickfhs Offline


Registered: 12/28/16
Posts: 1995
Loc: 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
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2006 Civic EX 200K/AT
2006 Acura TSX 177K/AT

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#4505825 - 09/02/17 09:15 PM Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs]
SnowDrifter Offline


Registered: 08/24/14
Posts: 391
Loc: WA
Build it up with weld, weld a nut to it, turn it out

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#4505827 - 09/02/17 09:23 PM Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs]
HangFire Offline


Registered: 08/21/13
Posts: 2506
Loc: 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.
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#4505845 - 09/02/17 09:53 PM Re: How to remove rusted 8mm bolt remnant? [Re: HangFire]
Ducked Online   content


Registered: 10/25/12
Posts: 4366
Loc: 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.

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#4505855 - 09/02/17 10:14 PM Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs]
Merkava_4 Offline


Registered: 01/30/07
Posts: 17501
Loc: Clovis, CA
I'd use a Proto extractor.


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#4505967 - 09/03/17 05:14 AM Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs]
WyrTwister Offline


Registered: 01/13/13
Posts: 1524
Loc: 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 .
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#4505978 - 09/03/17 05:46 AM Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs]
Trav Offline


Registered: 11/20/06
Posts: 18885
Loc: 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.
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#4505986 - 09/03/17 06:06 AM Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs]
LoneRanger Offline


Registered: 07/02/07
Posts: 4058
Loc: Midwest USA
Seeing only the subj line, thought you'd found an old Mauser rifle ...
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#4506001 - 09/03/17 07:27 AM Re: How to remove rusted 8mm bolt remnant? [Re: Ducked]
maverickfhs Offline


Registered: 12/28/16
Posts: 1995
Loc: 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.
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#4506004 - 09/03/17 07:31 AM Re: How to remove rusted 8mm bolt remnant? [Re: Trav]
maverickfhs Offline


Registered: 12/28/16
Posts: 1995
Loc: 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
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2006 Civic EX 200K/AT
2006 Acura TSX 177K/AT

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#4506083 - 09/03/17 09:32 AM Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs]
WyrTwister Offline


Registered: 01/13/13
Posts: 1524
Loc: 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
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#4506253 - 09/03/17 12:29 PM Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs]
Trav Offline


Registered: 11/20/06
Posts: 18885
Loc: 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.
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#4506374 - 09/03/17 03:27 PM Re: How to remove rusted 8mm bolt remnant? [Re: Trav]
maverickfhs Offline


Registered: 12/28/16
Posts: 1995
Loc: 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.
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2006 Civic EX 200K/AT
2006 Acura TSX 177K/AT

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#4506392 - 09/03/17 03:57 PM Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs]
AVB Offline


Registered: 05/20/12
Posts: 1283
Loc: 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.

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#4506395 - 09/03/17 04:03 PM Re: How to remove rusted 8mm bolt remnant? [Re: maverickfhs]
AVB Offline


Registered: 05/20/12
Posts: 1283
Loc: 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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