Removing Broken Easyout

d-dog · October 17, 2005

A friend had a minor accident on his motorcycle and broke off a bolt that holds his engine case protector. He drilled the 5/16 bolt and tried an easyout, but has broken it off flush with the top of the hole. I haven't seen it yet, but am looking for some suggestions on getting it out. I offered my marginal advice to use a drift to punch a slot in it, then use the slot to turn it out. Welding onto it could be pretty tough since it's so small and the access is pretty tight. Short of that, my only suggestion is to use a "cutting" rod on my arc welder and "blow" it out, but that's pretty messy.

Any suggestions?????

Thanx

Dog

MrQuadrasteer · October 17, 2005

Although it might be tough to do, left-handed drill bits kick butt and just might do it. But if it's a quality easy-out, it's going to be hardened and won't drill...

d-dog · October 17, 2005

Thanx - we may try that. It was the brand-name Easyout, and not one of the cheap import ones, so I'll assume it's hardened. I've taken an engine block down to a machine shop and used EDM to remove broken studs, but this is pretty inaccessible. Appreciate the advice.

Dog

abqchevyman · October 17, 2005

Buy and "end mill" carbide bit. This is about the only thing that will drill an easy out. You can get 3 or 5 flute, it doesn't matter. Being a 5/6" I would get an 1/8" or 3/32" if possible. Any bolt company should have an end mill or specialty tool company. Look to spend $15-20 for one.

It will be much cleaner than trying to blow it out and much easier.

Good luck.

builderpaul · October 17, 2005

Had that happen many years ago. My easyout was a high carbon steel and burned real easy. I used the cutting head on my oxyacet with a small tip. Blew out real clean.