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Broken Exhaust Bolt

harleyd72

harleyd72

Member
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.
 
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
 
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.
 
glider said:
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.
Click to expand...


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