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what are my options?

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haymeadow52

03-16-2005 22:53:33




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Farmall H water header cover plate...top rear 5/16" bolt broken off in casting almost flush with gasket surface...drilled and attempted to "easy out" and you guessed it! how am i going to get the broken "easy out" and the remaining bolt out of there? the bolt hole does not go through, but there is a pocket in the casting.
Any suggestions? Thanks.




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Opa A

03-17-2005 17:51:56




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 Re: what are my options? in reply to haymeadow52, 03-16-2005 22:53:33  
I have to agree with Andy Martin. If you don't feel comfortable welding through the hole in a nut, first weld a flat washer to the broken bolt/easy-out, then you can weld a larger nut to the washer. Try to get lots of heat into the broken bolt, quench it with some water and I bet it will back right out.



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wolfmantractor

03-17-2005 17:32:00




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 Re: what are my options? in reply to haymeadow52, 03-16-2005 22:53:33  
This method is not quick, but I have brought out many broken studs by tapping on a sharp chisel -make it gouge in around the outside circumference just short of the threads, The tap, tap of the hammer must be beneficial. Very sharp chisel; don't try to rush it.



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wolfmantractor

03-17-2005 17:38:57




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 Re: what are my options? in reply to wolfmantractor, 03-17-2005 17:32:00  
Usually the chisel has to be angled in between the broken off easy-out and the thread area. Often after the edge of the chisel has made nearly a hole, then a punch works better.



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dr.sportster

03-17-2005 08:22:29




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 Re: what are my options? in reply to haymeadow52, 03-16-2005 22:53:33  
The sears Craftsman type Dremel for 1/8" shaft has a couple shapes that work ok[ solid carbide].I ate up a broken 3/8 stud and extractor snapped in hole like this but went over a little and had to heli -coil the mess anyhow.I think 1/4" shaft bits will be a greater chance of thread damage.Oh, they are seven bucks each takes about two but are still usable after.Think Dentistry.



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dr.sportster

03-17-2005 08:31:46




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 Re: what are my options? in reply to dr.sportster, 03-17-2005 08:22:29  
Im such a bonehead I can never get my thoughts together and make one simple post.Id like to add the welding method is the best but before I went to sears I Tigged on about eight nuts and ran out of meat.Kept breaking off cause the stud was stuck so good.



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Andy Martin

03-17-2005 09:14:12




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 Re: what are my options? in reply to dr.sportster, 03-17-2005 08:31:46  
TIG or MIG may not put engouh heat on the stud to really loosen it. I've always had the best luck with stick electrode turned pretty warm.



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Andy Martin

03-17-2005 05:35:56




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 Re: what are my options? in reply to haymeadow52, 03-16-2005 22:53:33  
Put a nut over the hole and weld it to the broken bolt and easy out. They will back right out. The heat of welding will loosen the thread bond.

Don't worry about welding to the block, you can't with 6010 or 6011.

If you don't weld, get someone to do it. It is such a good method I go right to it and never try to drill a bolt out. If you drill off center you damage the threads. If the bolt is broken off below flush and you melt a little of the block, so what? You won't even lose the first complete thread.

I have used this manu many times and NEVER had a "failure".

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scotty

03-17-2005 05:11:45




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 Re: what are my options? in reply to haymeadow52, 03-16-2005 22:53:33  
Haymeadow, These guys have given some good advice. Like Dion said, EDM will do the job but how you gonna get the block to local machine shop. You might try to rent a magnetic mag motor drill. Its like a mini drill press that can be attached to your block preferably with a flat steel plate using the existing bolt holes from that cover. Get some 1/8" carbide drill bits and line the thing up and try to drill it out. Only a suggestion, and good luck!

scotty

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Paul in Mich

03-17-2005 05:10:06




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 Re: what are my options? in reply to haymeadow52, 03-16-2005 22:53:33  
Haymeadow, The "easyout" is made of tool steel, and may be anealed by using heat, then try drilling. If that doesnt work, try to find a carbide round nose grinding tool and grind out the "easyout". It takes patience, and do not apply a lot of pressure. Let the tool do the work. The last thing you want is to break a piece of carbide along with the tool steel, however, the redeeming grace is that carbide is brittle enough to shatter if smacked. Having worked in a machine shop, there were times that the only option to getting a broken drill or bolt out of a piece was to scrap the piece, which was really not an option. I"d say that 1/4 in carbide should work. Another thing to consider is keep everything from work hardening by not letting it get too hot while drilling or grinding. Good luck

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Dixieland

03-17-2005 04:41:41




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 Re: what are my options? in reply to haymeadow52, 03-16-2005 22:53:33  
Just be patient and magnify your determination! This has happened to me also and I just refused to give up but you have to be tactical or you can mess up even worse. I broke three bits on one, lost my religion twice, walked off and left it twice, but finally decided I was the boss and drilled, pecked, pried and worked till victory was mine. Now ain't that an option???? Good luck.



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MagMan

03-17-2005 03:51:51




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 Re: what are my options? in reply to haymeadow52, 03-16-2005 22:53:33  
Do You have access to a welder Or torches? Is there anything stick ing out still. How about a set of or carbide drill bits a machine shop nearby might be handy.If there is anything sticking out weld a bolt or nut on thatfor a head to turn the hole thing out but only afer you have heated it up a little. Or you can do as cowman sugested braze the cover hole up and drill a new one next to it. JON

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Nebraska Cowman

03-17-2005 03:23:03




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 Re: what are my options? in reply to haymeadow52, 03-16-2005 22:53:33  
I'd probably blow it out with a torch. But the resulting slag is hard to tap. Another option might be to drill and tap a new hole next to it



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Dion

03-17-2005 02:36:24




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 Re: what are my options? in reply to haymeadow52, 03-16-2005 22:53:33  
Since the easyout is hard, it will be brittle also. A sharp blow with another hardened punch may break it. MAKE SURE YOU WEARSAFETY GLASSES! Use a sharp pointed punch to increase the force of the blow.
I wish I had a nickle for every easyout or tap I have broken off.
A ram EDM will be expensive. There is a machine called a tap burner that does the same thing only slower. Many smaller machine shop have them because of the lower investment.
The only other method I know of is a dremel with a carbide burr. This is time consuming and requires patience. A dental pick will help get the pieces out after you cut it in half.
Good luck.

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greywynd

03-17-2005 00:27:54




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 Re: what are my options? in reply to haymeadow52, 03-16-2005 22:53:33  
This is a bit of a problem one. I'm guessing that the easy out broke off flush as well? It would be handy to know how much of the easy out is in it. Being hardened steel, there's only 2 ways to do anything to it. It either has to be ground with abrasive (maybe a Dremel tool or die grinder and grind it out?), the only other way I know of, is to EDM (electrical discharge maching). This really can only be done if the part in question can be taken to the machine, I've never seen a portable one.

I wish I had better news for you, maybe someone else will have another suggestion I'm not aware of. With it being in cast iron though, the options are limited....not like heating/welding, etc. are options that can really be used.

Mark

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