Broken Exhaust Bolt

Discussion in 'Dyna Models' started by harleyd72, Dec 22, 2011.

  1. harleyd72

    harleyd72 Member

    21
    0
    1
    Anyone have any tips for drilling through a broken easy out?

    Trying to install a set of V&H Big Radius and the front flange bolt broke. Drilled into it and tried a craftsman easy out which promptly broke and I couldn't get all of it out.

    I've gone through 3 cobalt bits trying to cut through it.
     
  2. fin_676

    fin_676 Experienced Member Staff Member Moderator Contributor

    5,276
    133
    156
    I think that perhaps you would be best to take the head off and take it to a machine shop who may be able to help as it is nearly impossible to drill out a broken easy out
    But you have got into a bad situation i have been there and had to get specialist help

    Brian
     
  3. harleyd72

    harleyd72 Member

    21
    0
    1
    Yeah, I'm hoping to avoid pulling the engine though.
     
  4. glider

    glider Veteran Member

    25,464
    108
    44
    Shouldn't have to pull the engine, as Brian said at the least is the head.Is there enough to grab on to above the deck height? If there is, some heat will work miracles.
     
  5. harleyd72

    harleyd72 Member

    21
    0
    1

    It's not a head bolt, it's an exhaust flange bolt, would have to take the cylinder off,
     
  6. fin_676

    fin_676 Experienced Member Staff Member Moderator Contributor

    5,276
    133
    156
    Exhaust port is part of the cylinder head and as such the flange studs are fitted into the cylinder head the bit above that is the rocker box

    Brian
     
  7. HDDon

    HDDon Experienced Member Contributor Retired Moderators

    5,456
    133
    196
    It would take a carbide endmill to get the broken parts of the easyout out. You will need to take the head to a machine shop so the head can be held tightly in a milling machine. It can also be removed with an EDM machine but either way the head needs to come off. I'm an old toolmaker and I really don't see a way to do it that doesn't involve disassembly.
     
  8. dangerdan

    dangerdan Junior Member

    922
    26
    0
    Just a thought. Can this carbide be welded. If so a new piece could be added making it easier to remove
     
  9. Webbtron

    Webbtron Banned

    583
    0
    1
    If the easy out is carbide it hard but brittle, if the heat doesn't help, try sharp taps at the weak points and it might fracture and then eventually tiny pieces will fall out. Do not use carbide as a center punch it will disintegrate in unpredictable ways. Nice sharp but sturdy point on some cold roll steel. Should work
     
  10. HDDon

    HDDon Experienced Member Contributor Retired Moderators

    5,456
    133
    196
    The easyout is usually made of hardened tool steel (rockwell C 61-64). I like the idea of having a welder welding a nut to the stud, but I still think the head will need to be removed so that the welder can have access.