Re: H - Drilling out fender bolt holes

Posted by Paul in Mich on December 23, 2003 at 08:37:54 from (68.188.227.110):

In Reply to: H - Drilling out fender bolt holes posted by Jim on December 23, 2003 at 07:41:16:

Jim, those broken off bolts aren't as hard to remove as one may think. Although this may not work in all cases, here's what I did. I laid out a 1/2 inch template with the bolt hole pattern. Two holes were drilled out to 1/2 inch and the other s to 1/4 inch. I then bolted the template to the 2 holes that were , and drilled 1/4 inch pilot holes in the 2 bolts that were broken off. I then sprayed "Blaster" into the holes and let them set over night. I tried an easy out the next day, but none came free. I opened the holes to 11/32 (.3437) and used a larger extractor and they came out without a hitch. Lucky for me, one side was mirror to the other side so I just flipped the template and used it for both sides. I then chased the threads with a bottom tap to clean out all the crud and installed new fender bolts using anti seize. I'm sure there are other ways, but this way worked well for me, and I didnt touch the existing threads with the drill bit.

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