Broken "easy out" the sequel to I keep breaking bolts :(

slartybarfast · 05-29-2006

We were working on a 70 gt and broke a bolt on the oil pump cover.

In the process of attempting to remove the bolt with the easy off we broke the easy off too.

whats the next step ? it seems the easy off is made of some pretty hard stuff.

neuropel · 05-29-2006

BAD news there! Easy-outs suck don't they?
There ARE hardened bits (cobalt coated or something?) that can drill the hardened easy-out metal. That hardened metal will just chew up the cutting edge on anything else you try. In situations where there's a bit of the bolt sticking out of the hole I've had better luck tacking on a bolt and slowly removing the broken bolt after heating it up good. If the easy out is broken down in the hole, the only thing I've seen work is a special hardened drill bit. McMaster Carr or similar may carry the hardened bits, or else talk to a local machine shop and see what they recommend.

I know that sinking feeling you get when this sort of thing happens. Let us know what ends up working for you!

Todd K.

opelnut10 · 05-29-2006

That is commenly known a "screwing the pooch" the best way to get the "easy out" back out is cut a slot in the end of it and use plenty of penitrating oil and back it out with a screwdriver. If that doesn't work make a gasket that blocks off the hole in the pump cover and just don't use that bolt. The other five will hold the cover on and if you use a drop of gasket sealer in the hole in the cover it will not leak.

namba209 · 05-29-2006

Oh boy, been there, done that. As Todd says that sucks, one of the reasons I try everything other than an easy-out now. Best thing I can recommend, and it will take a lot of time, is to get a Dremel carbide tipped grinder. They are really small so it will take some time to get the easy out ground away enuff so you can take it out. Patience is the key word here, there's no easy solution to it, you will have to take the time to grind it out. Same thing goes for a broken tap, but they're a bit easier because they are fluted and do not fill up the entire hole. The big thing is taking you time and go slowly, you don't want the bit to stray, it will eat into the aluminum very quickly. HTH.

opelbits · 05-29-2006

Not to make light of your predicament, but I was trying to figure out how oven cleaner was going to help with a broken bolt.

So, an easy-out has broken off? Is any of it sticking out of the hole or did it shear off below the surface? Since the easy-out is made of very hard material, you risk doing more damage by trying to drill it out in the car. If the easy-out broke off low or below the surface and if the fracture is nice and level, you might be able to center-punch it and then drill it out. To do that, you need some REALLY good drill bits just to cut the easy-out material. If you are able to do this, start off with a small bit (3/32 or 1/8) and drill it to the depth of the other holes, then step up in bit size gradually until you get to the size needed to retap the hole for the original bolt. I can't emphasize how important it is to drill staright and true. If you mess that up, you may be looking at replacing the whole cover. The problem is that the easy-out is hard, so the drill bit may wander (especially if you aren't dead-square with the housing surface) into the softer aluminum.

If sheared off above the surface, you *might* be able to grab it with Vise-Grips and with a combination of backing out the easy-out and judicious use of a brass hammer to jar it loose, it may come loose. Maybe.

If neither of these look like they will be effective or will cause more damage, then there is another way (actually it's alot like the first way, but more prep work is involved, but it will eliminate some risk and prevent taking the motor out). This works best if the easy-out broke pretty flat (unlikely) or sticks out. If it sticks out, stuff a rag into the oil pump cavity and use a file or something to make the easy-out flat and as parallel to the housing surface as you can get it.

This requires some precision work....get a piece of hardwood, oak is nice, and cut it into a block about the same size as the oil pump cover, but about 1 1/2" thick. Using the pump cover as a template, drill the block so it matches the bolt holes in the cover. Make the holes 1/8", then redrill all the holes to accept the same size bolt as the pump cover bolts. You want the holes snug, but not too tight. Do not enlarge the hole that will match-up with the broken easy-out. At this point, you should be able to bolt the block onto the timing cover with some longer bolts. The block will act as a drill guide to keep the drill bit nice and straight. This will only work if the easy-out is pretty flat and you use a good drill bit, carbide or something, otherwise, the drill bit will wander, deflect, and then break. If the easy-out cannot be flattened, then you may try drilling the hole in the wood block big enough to accept the drill bit required for the correct bolt size tap (or just under that size). Installing bronze bushings on either side of the block in that same hole will help control any possible wander due to the wood wearing away when the drill bit deflects.

It sounds a bit more complicated than it really is, but that is the trade off to not take the motor out.
How soon do you need this done? I may be able to make the drilling guide block for you. Can you post some pics?

slartybarfast · 05-30-2006

Originally Posted by opelbits

Not to make light of your predicament, but I was trying to figure out how oven cleaner was going to help with a broken bolt.

If one cant laugh what can they do ?

GTJIM · 05-30-2006

Forget trying to drill the easy-out out - too hard and any drill is sure to run off and chew ali.
Take the front cover off and find a Toolmaking shop that has an EDM (electric discharge machining) Tool for removing broken taps. This is a ghizmo that has an electrode sticking out of it that eats its way down through hardened metal using high frequency electricity - also known as 'spark erosion'
Toolmakers DO break taps !!

Some services: http://www.brokentap.com/index.html

http://www.twincityedm.com/brokenbolts.htm

HTH

05-29-2006	#1 (permalink)
slartybarfast Opeler Join Date: May 2005 Location: Tukwila Posts: 91 Classified Rating: 0% (0)	Broken "easy out" the sequel to I keep breaking bolts :( We were working on a 70 gt and broke a bolt on the oil pump cover. In the process of attempting to remove the bolt with the easy off we broke the easy off too. whats the next step ? it seems the easy off is made of some pretty hard stuff.

05-29-2006	#3 (permalink)
opelnut10 Living in the past Join Date: Oct 2005 Location: Virginia Posts: 1,197 Classified Rating: 0% (0)	Broken bolt That is commenly known a "screwing the pooch" the best way to get the "easy out" back out is cut a slot in the end of it and use plenty of penitrating oil and back it out with a screwdriver. If that doesn't work make a gasket that blocks off the hole in the pump cover and just don't use that bolt. The other five will hold the cover on and if you use a drop of gasket sealer in the hole in the cover it will not leak.

05-30-2006	#7 (permalink)
GTJIM 4246 Post Club Join Date: Jun 2003 Location: New Zealand Posts: 5,524 Classified Rating: 0% (0)	Hi Teck Forget trying to drill the easy-out out - too hard and any drill is sure to run off and chew ali. Take the front cover off and find a Toolmaking shop that has an EDM (electric discharge machining) Tool for removing broken taps. This is a ghizmo that has an electrode sticking out of it that eats its way down through hardened metal using high frequency electricity - also known as 'spark erosion' Toolmakers DO break taps !! Some services: http://www.brokentap.com/index.html http://www.twincityedm.com/brokenbolts.htm HTH Last edited by GTJIM; 05-30-2006 at 03:20 AM..

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05-29-2006	#2 (permalink)
neuropel Rice Cooker Join Date: May 2002 Location: Spring Church, PA Posts: 1,510 Classified Rating: 0% (0)	BAD news there! Easy-outs suck don't they? There ARE hardened bits (cobalt coated or something?) that can drill the hardened easy-out metal. That hardened metal will just chew up the cutting edge on anything else you try. In situations where there's a bit of the bolt sticking out of the hole I've had better luck tacking on a bolt and slowly removing the broken bolt after heating it up good. If the easy out is broken down in the hole, the only thing I've seen work is a special hardened drill bit. McMaster Carr or similar may carry the hardened bits, or else talk to a local machine shop and see what they recommend. I know that sinking feeling you get when this sort of thing happens. Let us know what ends up working for you! Todd K.

05-29-2006	#4 (permalink)
namba209 6,000 Post Club Join Date: Aug 2002 Location: Imperial Beach, CA South of San Diego Posts: 6,033 Classified Rating: 0% (0)	Oh boy, been there, done that. As Todd says that sucks, one of the reasons I try everything other than an easy-out now. Best thing I can recommend, and it will take a lot of time, is to get a Dremel carbide tipped grinder. They are really small so it will take some time to get the easy out ground away enuff so you can take it out. Patience is the key word here, there's no easy solution to it, you will have to take the time to grind it out. Same thing goes for a broken tap, but they're a bit easier because they are fluted and do not fill up the entire hole. The big thing is taking you time and go slowly, you don't want the bit to stray, it will eat into the aluminum very quickly. HTH.

05-29-2006	#5 (permalink)
opelbits Detritus Maximus Join Date: Jul 2002 Location: St. Louis MO Posts: 1,105 Classified Rating: 100% (1)	Not to make light of your predicament, but I was trying to figure out how oven cleaner was going to help with a broken bolt. So, an easy-out has broken off? Is any of it sticking out of the hole or did it shear off below the surface? Since the easy-out is made of very hard material, you risk doing more damage by trying to drill it out in the car. If the easy-out broke off low or below the surface and if the fracture is nice and level, you might be able to center-punch it and then drill it out. To do that, you need some REALLY good drill bits just to cut the easy-out material. If you are able to do this, start off with a small bit (3/32 or 1/8) and drill it to the depth of the other holes, then step up in bit size gradually until you get to the size needed to retap the hole for the original bolt. I can't emphasize how important it is to drill staright and true. If you mess that up, you may be looking at replacing the whole cover. The problem is that the easy-out is hard, so the drill bit may wander (especially if you aren't dead-square with the housing surface) into the softer aluminum. If sheared off above the surface, you might be able to grab it with Vise-Grips and with a combination of backing out the easy-out and judicious use of a brass hammer to jar it loose, it may come loose. Maybe. If neither of these look like they will be effective or will cause more damage, then there is another way (actually it's alot like the first way, but more prep work is involved, but it will eliminate some risk and prevent taking the motor out). This works best if the easy-out broke pretty flat (unlikely) or sticks out. If it sticks out, stuff a rag into the oil pump cavity and use a file or something to make the easy-out flat and as parallel to the housing surface as you can get it. This requires some precision work....get a piece of hardwood, oak is nice, and cut it into a block about the same size as the oil pump cover, but about 1 1/2" thick. Using the pump cover as a template, drill the block so it matches the bolt holes in the cover. Make the holes 1/8", then redrill all the holes to accept the same size bolt as the pump cover bolts. You want the holes snug, but not too tight. Do not enlarge the hole that will match-up with the broken easy-out. At this point, you should be able to bolt the block onto the timing cover with some longer bolts. The block will act as a drill guide to keep the drill bit nice and straight. This will only work if the easy-out is pretty flat and you use a good drill bit, carbide or something, otherwise, the drill bit will wander, deflect, and then break. If the easy-out cannot be flattened, then you may try drilling the hole in the wood block big enough to accept the drill bit required for the correct bolt size tap (or just under that size). Installing bronze bushings on either side of the block in that same hole will help control any possible wander due to the wood wearing away when the drill bit deflects. It sounds a bit more complicated than it really is, but that is the trade off to not take the motor out. How soon do you need this done? I may be able to make the drilling guide block for you. Can you post some pics?

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