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Old 04-17-2008, 09:19 PM
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broken bolt

I have a broken steel bolt in an aluminum head.The bolt is ground flush with head.It also has a broken easyout in it.
Can I use a mig welder with stainless steel wire to weld a bolt to it and try to back it out ?

Thanks King

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Old 04-17-2008, 09:38 PM
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Ouch, broken easy outs, drills and taps can be a real pain in the arse to get out. When it happens to me I usually have to chip the hard metal out because the things I work on usually aren't very portable.

What size bolt and easy out are broken off? How centered is the hole you drilled in the bolt? If you can chip the easy out up and get it out you could keep drilling the bolt out until you reach the tap drill size. Once you get close you can try a left handed drill bit, it may spin out. Otherwise you'll have to collapse the remains of the bolt in on itself and yank whats left with a pair of needle nose pliers. It can be tedious work.

Or you can take it to a machine shop and they can probably remove it for you.
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Old 04-17-2008, 09:43 PM
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If you don't want to try to drill & using a easy-out it first. Then weld a washer to broken bolt first, then weld the nut to the washer. That way you have good penetration on the broken bolt first then you use the nut to turn to get it out. And IF by some chance it all breaks off again, try & heat the broken bolt up & melt candle wax on it. The wax will seep down the threads & act like a lubricant, then drill & use a easy-out ....joe

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Old 04-17-2008, 09:57 PM
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Ah, sounds like a problem to me. I have done what blazin72 said. The easyout should be fairly brittle and you should be able to break it up into pieces with a small chisel/punch. It is hard to design an easyout because there must be a compromise between ductility and hardness when choosing the steel. Did you drill as large a hole as you could without hitting the threads? I have actually never tried welding another bolt to it. There won't be much room but maybe it would work if the weld is done well.
A really good trick is to heat it with a torch and melt wax onto it. The wax gets sucked into the threads and it will turn right out. I don't recommend this for your case though being an aluminum cylinder head and all. Another thing that I have never tried is using a dremel tool with some kind of diamond tip. This would get that easyout out.
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Old 04-17-2008, 10:04 PM
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I've removed lots of broken bolts by setting a steel nut over the broken
bolt and then use the wire feed welder to fill the hole. sometimes it takes
2 or 3 trys! never used stainless wire just plain steel wire.
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Old 04-18-2008, 12:11 AM
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If none of the above works, you will have to use EDM (electrical discharge machining) to get the whole mess out of there.
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