Bolt Extractor snapped.

[beswift]

Recently I've been working bringing a '94 4-R up to snuff. The undercarriage steel plate that guards the front of the vehicle was loose. I found that a bolt head had been snapped off while the bolt had siezed. I drilled it out and tried using a spiral extractor, but I snapped it off. Drilling with a cobalt tip, I can't make much progress on the hardened steel of the extractor. Is there any kind of drill bit that can penetrate it? I have also thought of finding a narrow cold chisel that can break up the extractor and allow me to remove it in pieces. Is that possible?

[Spectria, L1 MT]

Originally Posted by beswift

Recently I've been working bringing a '94 4-R up to snuff. The undercarriage steel plate that guards the front of the vehicle was loose. I found that a bolt head had been snapped off while the bolt had siezed. I drilled it out and tried using a spiral extractor, but I snapped it off. Drilling with a cobalt tip, I can't make much progress on the hardened steel of the extractor. Is there any kind of drill bit that can penetrate it? I have also thought of finding a narrow cold chisel that can break up the extractor and allow me to remove it in pieces. Is that possible?

A high speed carbide bit in a die grinder (very high speed) will grind it out but it takes a ton of practice to hold it dead steady and not let it vibrate and oscillate to the point where you shatter the carbide bit.

Good luck

[Brian R.]

Would it be possible to simply drill a new hole in the plate nearby the old broken bolt and drill/tap a new hole or nut in the matching frame surface to substitute for the missing bolt? I think it would be an easier approach and more likely to succeed.

JMHO

[JamieR]

I had a similar issue with my bash plate. I drilled out the bolt and tack welded a nut to the frame and then used some washers to keep it tight and square on both sides. Does sit a few centemeters lower but it saves you taping it out.