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post #1 of 51 Old 07-02-2019, 10:34 PM Thread Starter
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Broken bolts

I have at least two broken shroud bolts on my M18 Kohler. These are 1/4-20 bolts and obviously very rusted in. My plan is to drill a hole through them with a left-hand drill bit, partially because of the slim chance that the heat of drilling will break them loose and they'll unscrew, and then try to fill that new hole with PB Blaster and let them sit for a few days. After that I'll attempt to get them out with a screw extractor.
Does that sound like I might have a hope of getting them out of there? How about a better plan?

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post #2 of 51 Old 07-03-2019, 09:11 AM
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Re: Broken bolts

Should be relatively easy to get them out. Roger
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post #3 of 51 Old 07-03-2019, 10:00 AM
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Re: Broken bolts

Here is the best extractor set I've ever used:
https://www.ebay.com/itm/BLUE-POINT-...0AAOSwCwxdFjD5

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post #4 of 51 Old 07-03-2019, 10:58 AM
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Re: Broken bolts

I would just drill them out starting with a 1/8" bit and work your way up to whatever size drill you'd use to tap a 1/4" hole...then re-tap the hole,if the bolt doesn't come out while your drilling it..

I hate "screw extractors" and "E-Z Outs"..few ever have worked for me on anything that tiny--on bolts 3/8" or larger they might not snap off on you,but anything smaller they almost always break off,and present a larger problem to remove them..

I also use the welder on many smaller bolts--weld a flat washer to the broken bolt,then weld a hex nut to the washer,a MIG works best for this..often the heat from welding loosens the bolt and it'll come out fairly easily..


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post #5 of 51 Old 07-03-2019, 11:03 AM
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Re: Broken bolts

I'm definitely with tractor-holic on this one. I was able to drill one out well enough that, when I used the tap, it just cleaned out the original threads.

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post #6 of 51 Old 07-03-2019, 11:03 AM
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Re: Broken bolts

Don't think the PB will do much good in the drilled hole. Some claim heating it up and melting wax into the threads before removal works. I have never tried it.
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post #7 of 51 Old 07-03-2019, 11:28 AM
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Re: Broken bolts

Automatic transmission fluid and acetone in equal parts works better than most commercial penetrating oils and lots cheaper. Remember to use never seize on the new bolts!
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post #8 of 51 Old 07-03-2019, 12:14 PM
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Re: Broken bolts

Quote:
Originally Posted by burned300 View Post
Here is the best extractor set I've ever used:
https://www.ebay.com/itm/BLUE-POINT-...0AAOSwCwxdFjD5
I have to second this statement. The set is actually made for Blue Point by Rigid Tool. In a pinch I've drilled and then drove a Torx bit in and have been able to extract some broken screws/grease zerks that way.
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post #9 of 51 Old 07-03-2019, 12:18 PM Thread Starter
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I've been hearing about ATF and acetone for years, but have never tried it. these things are rusty as can be and broken off flush with the surface, so I might give it a shot.

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post #10 of 51 Old 07-03-2019, 12:20 PM
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Re: Broken bolts

If you drill, it is critical that you drill very carefully, and be certain the initial drill is centered in the broken off bolt. I think the block is likely aluminum, and those threads can be easily wrecked by a wandering drill.

Can you face the end of the bolt with a file or small grinder to make it as flat as possible, then use a punch to be sure your drill starts in the center? If you get a good starter hole, soak for a day or two with penetrating oil or home brew to increase the odds of it breaking loose if and when you try the easy out.

In all cases, don't be in a rush. Take your time and be very deliberate with the drill.

Good luck.
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post #11 of 51 Old 07-03-2019, 12:28 PM
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Re: Broken bolts

No love for EZ Outs. I would drill a 1/8 pilot hole. Then work up the diameters to 7/32. At that point, use a dental pick to clean remains of the bolt off the threads. Use a new 1/4 20 for a chasing tap. Takes awhile but I don't have a welder. I would buy a couple 1/8 bits and maybe 6 new bolts. Use lots of oil and go slow.
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post #12 of 51 Old 07-03-2019, 12:42 PM
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Re: Broken bolts

Every time I used an easyout on a rusted bolt it broke off and then was impossible to drill out. be careful
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post #13 of 51 Old 07-03-2019, 03:21 PM
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I have never had much success with extractors either. I always start with a sharp punch to center the hole and then use a starter bit, they have 60 degree flutes and a stubby shank so they do not wander. If you notice you are off center after stepping up a few drill sizes, you can drill till you almost see the threads on one side and use a small round file or dremel tool to carefully grind out the other side of the bolt, then pick away at the threads. Also if you use a tap to clean out the threads, after using a regular tap, use a bottom tap ( easily made by cutting off starter / taper threads off with a grinder ) so you get full threads right to the bottom of the hole.
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post #14 of 51 Old 07-03-2019, 07:24 PM
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Re: Broken bolts

Quote:
Originally Posted by Greg in WV View Post
I'm definitely with tractor-holic on this one. I was able to drill one out well enough that, when I used the tap, it just cleaned out the original threads.
I agree
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post #15 of 51 Old 07-03-2019, 08:01 PM
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Re: Broken bolts

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Originally Posted by Cnc View Post
Also if you use a tap to clean out the threads, after using a regular tap, use a bottom tap ( easily made by cutting off starter / taper threads off with a grinder ) so you get full threads right to the bottom of the hole.
I've never had to try it, but I've read that you can make a thread-chasing "tap" (just to clean up threads, not cut them from scratch). You start with a grade 8 bolt, then cut relief grooves lengthwise, with a grinder. The relief grooves provide room for stuff that the tap is scraping loose, so it doesn't just bind up the threads.
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