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Removing Broken bolts in Aluminum Castings

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SHU

03-08-2003 16:18:19

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Does anyone out there have a good method for removing a steel bolt that is flush with the surface of an aluminum casting? Any help with this problem would be greatly appreciated. Thanks.

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Alton

04-03-2003 19:45:42

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Re: Removing Broken bolts in Aluminum Castings in reply to SHU, 03-08-2003 16:18:19

Left hand drill and center punch in center of broken stud. Soak with peneteant a few days before trying to drill. Start small and work your way up. to just inside the thread surface then retap if stud has not come out while drilling.
Be sure you drill center and straight and slow.

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03-14-2003 15:33:11

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Re: Removing Broken bolts in Aluminum Castings in reply to SHU, 03-08-2003 16:18:19

AND..... DON'T EVER USE LOCTITE 'RED' WITH ALUMINUM AND STEEL.....YOU WILL HATE IT WHEN TRY TO TAKE THEM APART! L-T 'BLUE' WILL WORK, THOUGH.

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Hal/WA

03-10-2003 23:19:14

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Re: Removing Broken bolts in Aluminum Castings in reply to SHU, 03-08-2003 16:18:19

I recently had some success removing a broken off air cleaner stud that was stuck about 1/4" below the surface on the alloy carburetor of my Stihl chainsaw. I sprayed it full of PBBlaster and waited a few days. I remembered a kit I had bought from Sears awhile back called Screw Out. The tools in the kit are basicly reverse twist drill bits. The smallest bit in the kit fit down the hole. I used my cordless drill in reverse mode. About 3 or 4 seconds after the bit touched the broken off stud, it was out, without damaging the threads in the hole.

The kit cost about $20, but I had expected to spend lots more than that having a saw shop fix the problem. They suggested trying to drill it out normally and then putting in a bigger stud. That would have required a different method of holding down the air cleaner. Using the Sears tool made my problem a very easy fix. It might work for you.

With the bolt broken off right at the surface, I would try to make some kind of a jig to make sure your drilling is right in the center of the broken off bolt. I also would try soaking the casting in some kind of penetrating oil if it is possible to remove. And I might try heating it up some and then putting it back in the penetrating oil a few times. Sometimes steel bolts can really bond to aluminum and be real buggers to get out. Good luck!

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rhouston

03-10-2003 07:46:03

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Re: Removing Broken bolts in Aluminum Castings in reply to SHU, 03-08-2003 16:18:19

used to remove them from VW heads. Reverse drill seemed to work the best. Some heat helps as the aluminium expands more than steel. but be carefull not to use to much heat. most people advise to weld a nut to the stud and remove it that way. you can search the archives for complete directions on that approach. Aluninium and steel are not fun.

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Green Machine

06-18-2003 22:34:22

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Re: Re: Removing Broken bolts in Aluminum Castings in reply to rhouston, 03-10-2003 07:46:03

to not over heat alum, with actelyene torch apply black soot to metal then adjust flame to normal and heat when soot burns off do Not heat any longer this is just below the melting point. you can repeat the process

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