- Drilling out "snapped" bolts -

[imported_biocac]

There will come a time when eventually, a bolt can be snapped from overtightening, age, or natures "f. you" . . . (rust)

Here is a way to get that bolt stud out so you can fix the problem instead of having to replace parts, etc.

( *** FOR THIS WRITE-UP I AM USING THE SCENARIO OF A SNAPPED-OFF BOLT IN A DISK BRAKE CALIPER HOUSING/BRACKET *** ) * Taken from another "help" thread I posted in *


Anyways, here's what you do:

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Before you start, you'll need the following -

Punch
Hammer
Drill
Drill bit index
Either a reversed drill bit or an easy out (both can be rented from parts stores) * You'll want one almost the same size diameter of the bolt you'd like to remove!
Tap and Die kits will also come in handy if you can get one!

well . . lets get started:

1) Remove the caliper assembly from the car and get it on a bench were it's secured and you can reach it very easily.

2) Face the part were the bolt is snapped off towards you. Make sure that the bolt (were it snapped) is flat. If not, file/sand/dremel it flat.

3) Take the punch and place it on the bolt stud in the EXACT center. (the closer to center you punch it, the easier the rest will be.)

4) When you've got the punch were you need/want it, take your hammer and pound the punch. (This will create an indent in the stud) * Check it and make sure that you're still on center. If not, re-punch, if you are, put your punch back in the hole and whack it a few more times to really get a good indentation in the stud!

- Now . . Here is the trick . . You have to literally drill the center out of the stud with the drill bits. You have to use the smallest bit 1st, then work up through the bit index until you have drilled the center of the whole in the stud almost big enough so that you can see the threads in the "caliper bracket" -

* The key to this pretty much just boils down to Patience! *

5) When you run through all the drill bits necessary to complete the drilling process, you'll have to get the remaining metal out of the threads in the bracket whole or "thread boss"! . . .
That is were either the reversed bits, easy out, or tap/die kit comes in.

You can either "back out" the remaining metal

(some people just take a pick and carefully pry the metal out of the threads * being extremely careful not to damage the threads * but once again . . . if you do that, you must be very cautious!

When all of the metal files are out, you are done and can re-use your back to new part!

If you end up bitching up the internal threads while using the drill out procedure, you can always use the tap/die kit to re-thread to the next bolt size up OR just to run through a few times to "clean up" any unwanted imperfections.



* Now that the thread boss is made "new" again . . you can replace the empty whole with a new bolt!

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DONE
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SOURCE: http://www.civicland.com
DIY BY: Sam ( AKA ---> biocac)