Chad,
Broken bolt removal is always a little difficult. It sounds like you have
started to drill out the broken stud with a smaller drill bit, which then
broke off in the stud correct? Typically drill bits are made of very hard
materials are are difficult to drill. I have two suggestions, depending on
what tools you can access easily. The first is to use a Dremel with a
diamond drill bit. This has a diamond coating on the bitl which may allow
you to drill into remove the broken drill bit. If this works, you may be
able to still remove the broken bolt by using the method you started with.
Continue to drill the center of the bolt out until you are close to the size
of the threads in the block. Then you can use a screwdriver, pick or pliers
to grab the remaining threads of the bolt and remove them from the block. In
this case no rethreading/helicoil is necessary.
If you have more equipment (a welder) place a nut with diameter that fits
over the broken bolt. Weld the nut onto the bolt and use a socket to remove
the broken bolt. The heat from the welding usually helps loosen the broken
bolt.
There are probably some other good ways to do this as well.
GBergthold
From: Chad Rebuck <[email protected]>
To: 16v <[email protected]>
Subject: [a2-16v-list] removing broken bolt
Date: Mon, 8 Sep 2003 12:35:56 -0400 (EDT)
So I decide to replace the water pump on my 90 16v... One of the 4 bolts
that secures the water pump to the block has snapped, leaving only about a
1/4" exposed. I've tried liquid wrench, smacking the bolt with a hammer,
and propane torch all while trying to just get the bolt to break loose
with the vice grips. I gave up and attempted to drill it out and use a
heli-coil, but my small "starter" cobalt bit broke off in the bolt, so now
it is impossible to drill.
Any suggestions before I replace the block? There has to be some fitting
for my dremel or air grinder that could get through the bit in the bolt.
I am going to do some searches on the web to see what I can find.
Chad
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