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Old 11-23-2012, 10:22 AM   #1
mqo233 OP
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major engine broken bolt

on my 05, GS, the clutch went out, and the two bolts that hold the sub frame on, which you have to remove to swing the rear frame upward, well one broke. I went to loosen them, and it was tough, so I started sparying thread lubrication, I like areo koil, sparyed for days, finally, it was time, and it broke right off. not good. I got some left hand drill bits, to start drilling it out, things started out good, as the smaller bits went in really good. I have new bolts so I know how long they are, and I marked the bits, so as not to drill all the way. things went well for the first three bits. Number four broke inside the bolt, have ever tried to drill a drill bit out??? not good,

I decided to take a break and ask for any advise

thanks

James
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Old 11-23-2012, 10:56 AM   #2
onewheelwunder
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APPLY heat! It may have red thread locker on it. Heat guns work best, torch in a pinch
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Old 11-23-2012, 11:43 AM   #3
def
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If heat fails, EDM would be my next approach. I believe there are some portable EDM services out there.
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Old 11-23-2012, 01:05 PM   #4
mqo233 OP
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what is a EDM device
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Old 11-24-2012, 02:59 AM   #5
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I google the EMD device and could not find anyone in my town that has one, if someone knows where I could go, I am willing to travel to get this problem taken care of

thanks

James
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Old 11-24-2012, 05:04 AM   #6
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A carbide burr used in a Dremel tool will get rid of the broken drill, will take some time and patience though. If your drilled hole is center I would suggest a tap drill for the original size thread. That will leave just a small amount of thread from the original bolt to remove. A pick is handy for that.
I'm a tool & die maker so I get to do this often.
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Old 11-24-2012, 05:22 AM   #7
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the drilling out of broken bolts is one of the most difficult arts to master. There is a reason a master machinist makes a very good living. This is one of them. On a BMW, assume it has lock tight. I have several wire stands for my heat gun, so it can sit and do its thing while I take a break and walk around muttering random obscenities about German bikes, German engineers and German parts in general.. When the part is hot, they screw right out.

Then when it is back together, the Koolaid is so good!

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Old 11-24-2012, 09:06 AM   #8
def
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Edm

You might start here...

http://www.reliableedm.com/

But, I would follow the heat suggestion first...heat...as much as you dare apply.
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Old 11-24-2012, 09:44 AM   #9
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Assuming the drill bit you broke was a standard HSS drill, you could use a harder grade drill bit such as Cobalt steel (or better if you can find one), with lots of cooling, to drill out the broken drill. You will also need a steady hand or a means of keeping the drill square and centre whilst drilling.

The dremel sounds a very good idea if you can get a hard enough grinding burr for it, again it needs to be harder than the broken drill material. A Diamond burr would be good but I bet they are pricey and hard to find.

Patience is key, rushing the job usually causes more trouble than taking your time. good luck with it.
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Old 11-24-2012, 11:57 PM   #10
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Quote:
Originally Posted by mqo233 View Post
what is a EDM device
http://youtu.be/XfYXelZ4IaY

Reliable EDM
314 Garber Rd. Broussard, LA 70518
Ph (337) 839-4799 Fax (337) 839-4798


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Old 11-25-2012, 07:49 AM   #11
lhendrik
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I suggest you step back and consider the possibility that you are in over your head and get some help with this from a pro. Just my thought.
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Old 11-25-2012, 08:47 AM   #12
def
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Quote:
Originally Posted by mqo233 View Post
I google the EMD device and could not find anyone in my town that has one, if someone knows where I could go, I am willing to travel to get this problem taken care of

thanks

James
You're fortunate. If you will visit this website, you'll find that they are located just a few miles from you in Broussard. This is one of the foremost EDM shops in the country.

http://www.reliableedm.com/

Reliable EDM
314 Garber Rd. Broussard, LA 70518
Ph (337) 839-4799 Fax (337) 839-4798
E-Mail: phil@reliableedm.com
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Old 11-25-2012, 11:29 AM   #13
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BTDT. With my '04 GS. I was lucky and extracting broken drill bits was relatively straightforward. Once I bought some very high-quality drill bits everything went smoothly. Before that I was wondering what I was doing wrong.
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Old 11-25-2012, 01:18 PM   #14
mqo233 OP
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as to the drill bits, I purchased the most expensive left handed bits, thinking that would help get the bolt turning and maybe assist in the removal, I first drilled a pilot hold with a right handed cobalt bit, and as I see the first several went well,

I will be contacting the shop in Broussard on Monday,

thanks for all the help, I was able to get the other side out without any problem, I guess I just got the bit in a bad position,

we will see

thanks

James
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Old 11-25-2012, 01:21 PM   #15
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If the right-hand drill bits are working for you, you could try drilling out the old bolt completely, enlarge the hole in the engine case, and put in a helicoil. (This is what I did.)
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