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Post by volkswombat on May 24, 2018 15:03:49 GMT
Head snapped off a bolt on the round cover , tried drilling it out with a cobalt bit....it snapped. Tried welding blobs on and wrenching it out but didn't work. Took it to an old school engineers machine shop and explained there was a snapped bit in there too, no problem he says we can get it out but may need a helicoil. Today he phones up and says we can't do it , our machines won't touch it. Only way it's coming out is by spark erosion , whatever the fuck that is. He has started straight off by drilling out the bit of visible thread in the case. Nice.
So what's my next step.? The round cover wasn't actually leaking but I was going to do the seal anyway because I had the opportunity. The snapped bolt is at the top as the box is fitted, what are the chances it will not leak and I can just leave it with 2 bolts in? Any other bright ideas?
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Post by popegregoryxi on May 24, 2018 15:39:49 GMT
What a bastard! I'm out of bright ideas now, so I would be tempted to fill it with oil and see if it leaks..
Maybe @zed has a better snapped bolt removal tip.
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Post by chad on May 24, 2018 15:53:14 GMT
I'm tired so that is the excuse for the following:
Is it possible to rig up some sort of a clamp to fit where the bolt would be at one end and the other roughly opposite?
As the oil is not pressurised it shouldn't have to deal with much pressure and could be adjusted to even the pressure to that of the remaining bolts.
Even if it worked I'm not certain that it would be accepted at a MOT.
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Post by Zed on May 24, 2018 16:04:07 GMT
What a bastard! I'm out of bright ideas now, so I would be tempted to fill it with oil and see if it leaks.. Maybe @zed has a better snapped bolt removal tip. Not me guv. Weld was my last resort. Even with it clamped in a pillar drill it's not easy to prevent the drill going where it wants. Knowing this I'd have spent a fair time carefully cleaning the stub then a good blat at high amps, but my high amps was 180. Down one at about 150 was best. The first blat is all important, so as long and hot as you dare. I never let it cool before unscrewing either but have no idea if that's good, bad or impatience. When do we get a photo of the current mess state of it?
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Post by volkswombat on May 24, 2018 16:07:40 GMT
What a bastard! I'm out of bright ideas now, so I would be tempted to fill it with oil and see if it leaks.. Maybe @zed has a better snapped bolt removal tip. Yeah it is a bastrad! I fail to see how a machine shop can't bloody do it !! Think I'll try the leak test and hope for the best
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Post by volkswombat on May 24, 2018 16:09:50 GMT
I'm tired so that is the excuse for the following: Is it possible to rig up some sort of a clamp to fit where the bolt would be at one end and the other roughly opposite? As the oil is not pressurised it shouldn't have to deal with much pressure and could be adjusted to even the pressure to that of the remaining bolts. Even if it worked I'm not certain that it would be accepted at a MOT. I thought of that too, no idea if such a thing exists though....like a g clamp but tiny and using a nut/bolt
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Post by volkswombat on May 24, 2018 16:12:41 GMT
What a bastard! I'm out of bright ideas now, so I would be tempted to fill it with oil and see if it leaks.. Maybe @zed has a better snapped bolt removal tip. Not me guv. Weld was my last resort. Even with it clamped in a pillar drill it's not easy to prevent the drill going where it wants. Knowing this I'd have spent a fair time carefully cleaning the stub then a good blat at high amps, but my high amps was 180. Down one at about 150 was best. The first blat is all important, so as long and hot as you dare. I never let it cool before unscrewing either but have no idea if that's good, bad or impatience. When do we get a photo of the current mess state of it? Will get a pic in a bit. Is it odd that they've fucked the threads straight off ? Just looks like they've gone straight in with a huge drill bit
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Post by volkswombat on May 24, 2018 16:25:58 GMT
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Post by popegregoryxi on May 24, 2018 16:34:59 GMT
Fuck they went in big didn't they! On à positive note, they have left you with a nice clean stub end, and plenty of room... how powerful is your welder? I would try the weld method again if it's powerful enough, as zed says, as much heat as you dare...
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Post by popegregoryxi on May 24, 2018 16:37:57 GMT
If you have a die grinder, or dremel type thing, shine up the stub end first.
Or just say Fuck it and leave it alone..
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Post by Zed on May 24, 2018 16:55:33 GMT
At this point I'd probably loose my temper, support underneath with a block of wood and try to smash it through with a 4lb lump hammer and large punch. Having then broken the corner off doing that I'd bodge it together with a nut and bolt through whatever was left of the hole.
No need to thank me. 👍
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Post by Zed on May 24, 2018 16:59:15 GMT
Seriously though, there can't be much left of the drill you snapped off? Maybe try and punch out what's left of the broken drill, it looks quite small.
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Post by Baz on May 24, 2018 17:18:33 GMT
Could you not put it under a brake press and push it out ?
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Post by pkrboo on May 24, 2018 17:26:13 GMT
Spark erosion would have that out in ten minutes.
Find a newer school machine shop and they should be able to do it.
I had some cylinder heads from a 300zx turbo with broken studs and they got them out easy.(this was in America) but a place in UK will be able to do it.
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Post by volkswombat on May 24, 2018 17:29:05 GMT
Seriously though, there can't be much left of the drill you snapped off? Maybe try and punch out what's left of the broken drill, it looks quite small. I'm a bit pissed a bout that, because when the bit snapped, it was maybe 5mm from being through the end of the bolt, I reckon I could of drilled from the blind side till I hit the snapped bit , then as you say punched it out, and carry on getting the bloody bolt out and saving the thread. All with a fucking black and decker workmate and 18v Makita drill and my own ineptitude. But I decided to hand it over to a fucking professional with lathes, pillar drills, all the proper tools, years of experience, so I don't fuck it up and oh look, they fuck it up.
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