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Author Topic: Extracting a broken bolt?  (Read 185 times)
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JeepReviews
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« on: August 27, 2011, 05:11:15 PM »

While removing the stock rear bumper from my super-rusty TJ, I snapped the head off of one of the bolts that goes into the frame. It's one of the 1/2" bolts that goes up vertically from bottom of bumper into frame.  Unfortunately, my adventure didn't end there. I decided that I was going to drill it out. Yep, I snapped the drillbit inside the bolt when drilling the pilot hole (retard).

So, that leaves me with a broken 1/2" bolt with a broken titanium drillbit inside of it (awesome).  The bolt is pretty much flush with the bottom of the frame. Do you think it's possible that I could find someone to weld a nut onto the bolt and extract it that way?  Any other thoughts on what I can do (besides burning it out w/ torch or plasma cutter)?

Thanks,
-Garrett


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« Reply #1 on: August 27, 2011, 06:20:30 PM »

Can you get the drill bit out?  You could try welding a nut, or you can cut the whole thing out, and weld in a new piece of metal with a nut welded on the inside. 
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« Reply #2 on: August 27, 2011, 08:08:05 PM »

Don't think I can get the bit out b/c it's so small, 5/64"
Would really like to avoid having the whole thing cut out.
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« Reply #3 on: August 27, 2011, 08:20:40 PM »

try carefully drilling with (a quality metal drill) the largest size you can, without drilling the threads?
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« Reply #4 on: August 27, 2011, 08:33:44 PM »

Depending on how well the thread insert is welded to the inside of the frame, you can punch it out and through bolt it.  I run into this all of the time and that's what I do.  Just drop a bolt down through the frame and nut it on the bottom.  Some thread inserts are welded all around and can be difficult to remove.
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