Help!! broken off easy out (Huge Pics)

Help!!!! Ok guys here is the deal I had a bolt head snap off in the frame for my CR500. It’s the bolt that holds the exhaust on to the frame down tube (see pictures). Here is the problem I drilled the bolt out and tried to use an easy out to get it out. Well the easy out broke off. Now I can’t drill it out anyone have any ideas how to solve this problem



Thanks in advance

I left them full sized so you could really see what i was talking about

http://i159.photobucket.com/albums/t...o/DSC_0712.jpg
http://i159.photobucket.com/albums/t...o/DSC_0711.jpg
http://i159.photobucket.com/albums/t...o/DSC_0708.jpg

tack weld a bolt to it and use a nut to fasten it?

Seen it happen before and done it myself.First step file it all down so that it is smooth then center punch a small hole in the middle to stop the drill bit skidding all over the place , then drill the whole lot out starting with a very small drill bit and go up in size as you go.While you are drilling apply lots of oil to cool and lube the drill bits or you will burn them out vey fast or worse yet snap them as well , once you got it all out re-tap a new thread you may need to go up a size of bolt at which point enlarge the hole on the mounting flange on the pipe.Rember take your time and don't rush it .Hope this helps you out it's worked for me a few times.

Originally Posted by THE JESTER

Seen it happen before and done it myself.First step file it all down so that it is smooth then center punch a small hole in the middle to stop the drill bit skidding all over the place , then drill the whole lot out starting with a very small drill bit and go up in size as you go.While you are drilling apply lots of oil to cool and lube the drill bits or you will burn them out vey fast or worse yet snap them as well , once you got it all out re-tap a new thread you may need to go up a size of bolt at which point enlarge the hole on the mounting flange on the pipe.Rember take your time and don't rush it .Hope this helps you out it's worked for me a few times.

Used this method too and it works

There are also revers drill bits that turn counterclockwise. These are good for broken bolts as they drill out the bolts and turn them out at the same time.

as I understood you have a hard piece of easy out broken in the hole.
you can try to destroy it using a high speed drill like this:
Proxxon Trapano fresatore industriale IB-E da D'Amico forniture

(just to give you an idea oh wich kind of tool i mean)
using carbon metal (VIDIA) tools.
I was mould maker and we used that kind of tools to drill and mill hard metal.

or you can try to drill a hole on the opposite side of the tube and knock out the piece.
it seem insulting but extreem problem sometimes need extreem solution.

mine is just a suggestion

[Weasle1000RR]

You sir, have the largest pictures in the land.

try a cobalt drill as carbide is strong it is too brittle and will brake easier,
low rps, should work if it all fails look up deburring shops in your area as they can burn out broken taps with a electric discharge machine, they should be able to burn out the easy out.

Originally Posted by libretto

Help!!!! Ok guys here is the deal I had a bolt head snap off in the frame for my CR500. It’s the bolt that holds the exhaust on to the frame down tube (see pictures). Here is the problem I drilled the bolt out and tried to use an easy out to get it out. Well the easy out broke off. Now I can’t drill it out anyone have any ideas how to solve this problem



Thanks in advance
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You cannot drill out an ez-out unless you have VERY expensive bits, i believe diamond bits. I had this happen in a cylinder head and had to get it dilled out on a mill with a $100 bit. Your best bet, like some one said is to get behind it(if possible) and knock it out, drill tiny holes around without breaking that bit and try picking it out. Not sure if you know how to weld, but another option would be to just grind off the welded threaded bung and reweld a new one.

Good luck, let us know how you make out!

[lanbrown]

For proplr that search, they will find more options. The OP posted his question over a year ago.

[BigLakeBR]

They actually sell special tools for this, you can buy them from Snap-on!