Broken bolt removal?! need help.
Thread Starter
Intermediate
Joined: May 2013
Posts: 47
Likes: 0
Broken bolt removal?! need help.
As I was putting the fuel pump plate back on, the old bolt snapped and it was the worst case scenario .... the half the the bolt is not even sticking out... does any have any suggestions besides pulling the motor out.. Please help
Burning Brakes
Joined: Jun 2010
Posts: 1,165
Likes: 93
From: Bellmore NY
Ok you are in a crappy spot, but hopefully you can get out relatively painlessly.
My first attempt would be with a right angle die grinder and an e-z out. And a lot of patience.
If that didn't work, I would possibly try a chisel small enough to fit in the hole, and gouge a slot into the bolt face, and try to use a screw driver to remove it.
My first attempt would be with a right angle die grinder and an e-z out. And a lot of patience.
If that didn't work, I would possibly try a chisel small enough to fit in the hole, and gouge a slot into the bolt face, and try to use a screw driver to remove it.
Thread Starter
Intermediate
Joined: May 2013
Posts: 47
Likes: 0
its completely stuck in there and this spot isnt able to fit a drill or anything whatso ever /= any other suggestions?? how can the welder help??
Le Mans Master
Joined: Oct 2006
Posts: 7,123
Likes: 433
From: Gladstone MO
C3 of Year Finalist (appearance mods) 2019
A small right angle drill with a #10 bit. Drill it down the center. I know which pair of bolts your looking at- I have a BB also. It's not going to be easy. I have a DOTCO 90* drill but they are not cheap. They also make small 90* adapters you can use with a standard drill.
http://www.chiefaircraft.com/ca-5130.html
The bits have a threaded shank so you'll also need to get a couple of those. For the 3/8 bolts, I'd use a #10 bit. And they have those that are less than 1/2" long.
http://www.chiefaircraft.com/ca-5130.html
The bits have a threaded shank so you'll also need to get a couple of those. For the 3/8 bolts, I'd use a #10 bit. And they have those that are less than 1/2" long.
Thread Starter
Intermediate
Joined: May 2013
Posts: 47
Likes: 0
A small right angle drill with a #10 bit. Drill it down the center. I know which pair of bolts your looking at- I have a BB also. It's not going to be easy. I have a DOTCO 90* drill but they are not cheap. They also make small 90* adapters you can use with a standard drill.
http://www.chiefaircraft.com/ca-5130.html
The bits have a threaded shank so you'll also need to get a couple of those. For the 3/8 bolts, I'd use a #10 bit. And they have those that are less than 1/2" long.
http://www.chiefaircraft.com/ca-5130.html
The bits have a threaded shank so you'll also need to get a couple of those. For the 3/8 bolts, I'd use a #10 bit. And they have those that are less than 1/2" long.
Melting Slicks
Joined: May 2005
Posts: 2,486
Likes: 71
From: Elkhart Lake, Wisconsin
You put a nut over the hole and then weld through the nut to the broken bolt welding the broken part to the nut. The heat loosens the old bolt and you use a wrench to turn the nut with the now welded broken bolt out.
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Advanced
Joined: Jan 2013
Posts: 99
Likes: 3
From: Salem Ohio
Try a dremel with a flexible extension and a 1/16th bit be patient drill as close to center as you can and the use a small easy-out. With the fuel pump off and the plate removed you will get in there. It is all feel as you will not see inside but you can do it. You may have to shorten the bit and use tape to mark how deep you drill.
Race Director
Joined: Mar 2006
Posts: 14,112
Likes: 28
From: Florida
I wouldn't get in a tizzy over it if you can't get it.
If the broken bolt is one of the lower 2 just for the plate, you can forget about it and just use a good sealant like Permatex Right Stuff, then bolt the pump on. Guaranteed it won't leak.
Fix it if and whenever you pull the engine.
If the broken bolt is one of the lower 2 just for the plate, you can forget about it and just use a good sealant like Permatex Right Stuff, then bolt the pump on. Guaranteed it won't leak.
Fix it if and whenever you pull the engine.
Team Owner
Joined: Jan 2006
Posts: 37,637
Likes: 3,116
From: Crossville TN
Surely the broken bolt shank is somewhere close to the machined surface of the block.? If so, you could use a Dremel with a thin cut-off wheel to grind a slot [for a screwdriver] into the end of that shank. Yes, you would have to grind that same slot into the engine block, somewhat. But, that shouldn't cause any functional problem for the block. Then....maybe....you could get a 'stubby' screwdriver in there and back out the broken bolt shank.
If you do this, and are successful, you can put a 'dummy' bolt in that threaded hole and pack some JB Weld [stick] epoxy down into those machined slots on either side of the hole. Scrape the excess off the surface and remove the 'dummy' bolt. That should take care of the cosmetic issues.
Now, next time, don't torque that little bolt so much. Or, maybe the cam was rotated to 'pump apply' position and you were trying to use that bolt to "crank" that fuel pump in place. Bad idea, if that's what happened. [Crank the engine over to rotate cam to no-load position on the fuel pump. It's easier to assemble that way.] Or, was the bolt you used too long for the hole?
There's some reason for snapping that puppy off. Whatever it was, don't do that again!
If you do this, and are successful, you can put a 'dummy' bolt in that threaded hole and pack some JB Weld [stick] epoxy down into those machined slots on either side of the hole. Scrape the excess off the surface and remove the 'dummy' bolt. That should take care of the cosmetic issues.
Now, next time, don't torque that little bolt so much. Or, maybe the cam was rotated to 'pump apply' position and you were trying to use that bolt to "crank" that fuel pump in place. Bad idea, if that's what happened. [Crank the engine over to rotate cam to no-load position on the fuel pump. It's easier to assemble that way.] Or, was the bolt you used too long for the hole?
There's some reason for snapping that puppy off. Whatever it was, don't do that again!
Thread Starter
Intermediate
Joined: May 2013
Posts: 47
Likes: 0
Surely the broken bolt shank is somewhere close to the machined surface of the block.? If so, you could use a Dremel with a thin cut-off wheel to grind a slot [for a screwdriver] into the end of that shank. Yes, you would have to grind that same slot into the engine block, somewhat. But, that shouldn't cause any functional problem for the block. Then....maybe....you could get a 'stubby' screwdriver in there and back out the broken bolt shank.
If you do this, and are successful, you can put a 'dummy' bolt in that threaded hole and pack some JB Weld [stick] epoxy down into those machined slots on either side of the hole. Scrape the excess off the surface and remove the 'dummy' bolt. That should take care of the cosmetic issues.
Now, next time, don't torque that little bolt so much. Or, maybe the cam was rotated to 'pump apply' position and you were trying to use that bolt to "crank" that fuel pump in place. Bad idea, if that's what happened. [Crank the engine over to rotate cam to no-load position on the fuel pump. It's easier to assemble that way.] Or, was the bolt you used too long for the hole?
There's some reason for snapping that puppy off. Whatever it was, don't do that again!
If you do this, and are successful, you can put a 'dummy' bolt in that threaded hole and pack some JB Weld [stick] epoxy down into those machined slots on either side of the hole. Scrape the excess off the surface and remove the 'dummy' bolt. That should take care of the cosmetic issues.
Now, next time, don't torque that little bolt so much. Or, maybe the cam was rotated to 'pump apply' position and you were trying to use that bolt to "crank" that fuel pump in place. Bad idea, if that's what happened. [Crank the engine over to rotate cam to no-load position on the fuel pump. It's easier to assemble that way.] Or, was the bolt you used too long for the hole?
There's some reason for snapping that puppy off. Whatever it was, don't do that again!
Thread Starter
Intermediate
Joined: May 2013
Posts: 47
Likes: 0
hey guys I got it out !! all it took was a small hand dremel and a extractor kit and the second it touched the screws end ( after I wd-40'd the hell out of it ) it soin right out !! this is why I love this hobby, you never know what can happen until you try it !