Re: Best method for extracting bolts with broken off heads...
 

Well, it must be time for a progress report...

First, I tried the torch, followed by an extractor. I managed to snap the
extractor off in the bolt. *sigh* I think my neighbor jinxed me on that
one, cuz he warned me about it.

I was able to cut off the bolt and get the remains of the extractor out, so
no real harm done, anyway. I followed that up with a titanium coated bit,
to try drilling it out. I think I should have used a beefier (or better)
bit, as the bit busted off inside. *sigh again*

So I picked up some better and bigger bits, and went at it again tonight.
First, I had to remove the front of the Jeep, so I could get my drill in
there. Turns out to be pretty easy (4 bolts, hidden behind the turn
signals, in case you need to know), although I'm a little nervous about
getting everything lined up again (assuming I get to put it back together
some time). Gives me lots more room to work, anyway.

I got the bottom bolt drilled out pretty quick, and I THINK I'll be ok with
the threads. I'll have to wait and see on that one; the remains of the bolt
showed just the very end threads to be touched by the drill bit.. But the
top bolt is still stuck tight, and the real problem now is the broken drill
bit in it is keeping me from drilling it out.

I saw someone else with a stuck tap in this same thread, and the suggestion
was a carbide bit, an A/C drill, and a case of beer (or something like
that). I think I'll pass on the beer (too many memories of New Year's Eve),
but I'll break out my old corded drill and pick up a few more bits to try
drilling it out.

Hey, at least I won ONE fight tonight. :)

Clint

"Clint" <cneufeld@mysocks.shaw.ca> wrote in message
news:UJCkh.535564$R63.397938@pd7urf1no...
> So I'm elbows-deep in pulling out my radiator and water pump from my '88
> Jeep Comanche (4.0l, if that matters), and as I figured was likely, two
> bolt heads broke off. I've got pictures, if you care to see
> (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're
> broken off just under the head, so there's about 1/2" of threaded material
> to grab, assuming that doesn't break off.
>
> What's the best method you've found to deal with these? Do any of them
> work better than others? If I've got to drill a hole in them, how do you
> get the hole started with an uneven surface like the broken off head?
> Center-punch? That'll be fun to get in there with a hammer...
>
> So far, I figure I'm about 3 hours into the job, and I've got all the old
> parts out. The old water pump actually looks like it's in good shaped
> (vanes all there, looking pretty new), but it was leaking. There was no
> sign of anything other than the paper gasket; should I be using the RTV
> gasket gunk as well? Somehow, I've got to get into the block heater and
> replace it as well. At least with the water pump out, I can see in there
> a bit.
>
> Clint

Re: Best method for extracting bolts with broken off heads...
 

Well, it must be time for a progress report...

First, I tried the torch, followed by an extractor. I managed to snap the
extractor off in the bolt. *sigh* I think my neighbor jinxed me on that
one, cuz he warned me about it.

I was able to cut off the bolt and get the remains of the extractor out, so
no real harm done, anyway. I followed that up with a titanium coated bit,
to try drilling it out. I think I should have used a beefier (or better)
bit, as the bit busted off inside. *sigh again*

So I picked up some better and bigger bits, and went at it again tonight.
First, I had to remove the front of the Jeep, so I could get my drill in
there. Turns out to be pretty easy (4 bolts, hidden behind the turn
signals, in case you need to know), although I'm a little nervous about
getting everything lined up again (assuming I get to put it back together
some time). Gives me lots more room to work, anyway.

I got the bottom bolt drilled out pretty quick, and I THINK I'll be ok with
the threads. I'll have to wait and see on that one; the remains of the bolt
showed just the very end threads to be touched by the drill bit.. But the
top bolt is still stuck tight, and the real problem now is the broken drill
bit in it is keeping me from drilling it out.

I saw someone else with a stuck tap in this same thread, and the suggestion
was a carbide bit, an A/C drill, and a case of beer (or something like
that). I think I'll pass on the beer (too many memories of New Year's Eve),
but I'll break out my old corded drill and pick up a few more bits to try
drilling it out.

Hey, at least I won ONE fight tonight. :)

Clint

"Clint" <cneufeld@mysocks.shaw.ca> wrote in message
news:UJCkh.535564$R63.397938@pd7urf1no...
> So I'm elbows-deep in pulling out my radiator and water pump from my '88
> Jeep Comanche (4.0l, if that matters), and as I figured was likely, two
> bolt heads broke off. I've got pictures, if you care to see
> (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're
> broken off just under the head, so there's about 1/2" of threaded material
> to grab, assuming that doesn't break off.
>
> What's the best method you've found to deal with these? Do any of them
> work better than others? If I've got to drill a hole in them, how do you
> get the hole started with an uneven surface like the broken off head?
> Center-punch? That'll be fun to get in there with a hammer...
>
> So far, I figure I'm about 3 hours into the job, and I've got all the old
> parts out. The old water pump actually looks like it's in good shaped
> (vanes all there, looking pretty new), but it was leaking. There was no
> sign of anything other than the paper gasket; should I be using the RTV
> gasket gunk as well? Somehow, I've got to get into the block heater and
> replace it as well. At least with the water pump out, I can see in there
> a bit.
>
> Clint

Re: Best method for extracting bolts with broken off heads...
 

Nice work on the one. You'll get the second one eventually.

Carl


"Clint" <cneufeld@mysocks.shaw.ca> wrote in message
news:ns%mh.557918$R63.81715@pd7urf1no...
> Well, it must be time for a progress report...
>
> First, I tried the torch, followed by an extractor. I managed to snap the
> extractor off in the bolt. *sigh* I think my neighbor jinxed me on that
> one, cuz he warned me about it.
>
> I was able to cut off the bolt and get the remains of the extractor out,
> so no real harm done, anyway. I followed that up with a titanium coated
> bit, to try drilling it out. I think I should have used a beefier (or
> better) bit, as the bit busted off inside. *sigh again*
>
> So I picked up some better and bigger bits, and went at it again tonight.
> First, I had to remove the front of the Jeep, so I could get my drill in
> there. Turns out to be pretty easy (4 bolts, hidden behind the turn
> signals, in case you need to know), although I'm a little nervous about
> getting everything lined up again (assuming I get to put it back together
> some time). Gives me lots more room to work, anyway.
>
> I got the bottom bolt drilled out pretty quick, and I THINK I'll be ok
> with the threads. I'll have to wait and see on that one; the remains of
> the bolt showed just the very end threads to be touched by the drill bit..
> But the top bolt is still stuck tight, and the real problem now is the
> broken drill bit in it is keeping me from drilling it out.
>
> I saw someone else with a stuck tap in this same thread, and the
> suggestion was a carbide bit, an A/C drill, and a case of beer (or
> something like that). I think I'll pass on the beer (too many memories of
> New Year's Eve), but I'll break out my old corded drill and pick up a few
> more bits to try drilling it out.
>
> Hey, at least I won ONE fight tonight. :)
>
> Clint
>
> "Clint" <cneufeld@mysocks.shaw.ca> wrote in message
> news:UJCkh.535564$R63.397938@pd7urf1no...
>> So I'm elbows-deep in pulling out my radiator and water pump from my '88
>> Jeep Comanche (4.0l, if that matters), and as I figured was likely, two
>> bolt heads broke off. I've got pictures, if you care to see
>> (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're
>> broken off just under the head, so there's about 1/2" of threaded
>> material to grab, assuming that doesn't break off.
>>
>> What's the best method you've found to deal with these? Do any of them
>> work better than others? If I've got to drill a hole in them, how do you
>> get the hole started with an uneven surface like the broken off head?
>> Center-punch? That'll be fun to get in there with a hammer...
>>
>> So far, I figure I'm about 3 hours into the job, and I've got all the old
>> parts out. The old water pump actually looks like it's in good shaped
>> (vanes all there, looking pretty new), but it was leaking. There was no
>> sign of anything other than the paper gasket; should I be using the RTV
>> gasket gunk as well? Somehow, I've got to get into the block heater and
>> replace it as well. At least with the water pump out, I can see in there
>> a bit.
>>
>> Clint
>

Re: Best method for extracting bolts with broken off heads...
 

Nice work on the one. You'll get the second one eventually.

Carl


"Clint" <cneufeld@mysocks.shaw.ca> wrote in message
news:ns%mh.557918$R63.81715@pd7urf1no...
> Well, it must be time for a progress report...
>
> First, I tried the torch, followed by an extractor. I managed to snap the
> extractor off in the bolt. *sigh* I think my neighbor jinxed me on that
> one, cuz he warned me about it.
>
> I was able to cut off the bolt and get the remains of the extractor out,
> so no real harm done, anyway. I followed that up with a titanium coated
> bit, to try drilling it out. I think I should have used a beefier (or
> better) bit, as the bit busted off inside. *sigh again*
>
> So I picked up some better and bigger bits, and went at it again tonight.
> First, I had to remove the front of the Jeep, so I could get my drill in
> there. Turns out to be pretty easy (4 bolts, hidden behind the turn
> signals, in case you need to know), although I'm a little nervous about
> getting everything lined up again (assuming I get to put it back together
> some time). Gives me lots more room to work, anyway.
>
> I got the bottom bolt drilled out pretty quick, and I THINK I'll be ok
> with the threads. I'll have to wait and see on that one; the remains of
> the bolt showed just the very end threads to be touched by the drill bit..
> But the top bolt is still stuck tight, and the real problem now is the
> broken drill bit in it is keeping me from drilling it out.
>
> I saw someone else with a stuck tap in this same thread, and the
> suggestion was a carbide bit, an A/C drill, and a case of beer (or
> something like that). I think I'll pass on the beer (too many memories of
> New Year's Eve), but I'll break out my old corded drill and pick up a few
> more bits to try drilling it out.
>
> Hey, at least I won ONE fight tonight. :)
>
> Clint
>
> "Clint" <cneufeld@mysocks.shaw.ca> wrote in message
> news:UJCkh.535564$R63.397938@pd7urf1no...
>> So I'm elbows-deep in pulling out my radiator and water pump from my '88
>> Jeep Comanche (4.0l, if that matters), and as I figured was likely, two
>> bolt heads broke off. I've got pictures, if you care to see
>> (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're
>> broken off just under the head, so there's about 1/2" of threaded
>> material to grab, assuming that doesn't break off.
>>
>> What's the best method you've found to deal with these? Do any of them
>> work better than others? If I've got to drill a hole in them, how do you
>> get the hole started with an uneven surface like the broken off head?
>> Center-punch? That'll be fun to get in there with a hammer...
>>
>> So far, I figure I'm about 3 hours into the job, and I've got all the old
>> parts out. The old water pump actually looks like it's in good shaped
>> (vanes all there, looking pretty new), but it was leaking. There was no
>> sign of anything other than the paper gasket; should I be using the RTV
>> gasket gunk as well? Somehow, I've got to get into the block heater and
>> replace it as well. At least with the water pump out, I can see in there
>> a bit.
>>
>> Clint
>

Re: Best method for extracting bolts with broken off heads...
 

Nice work on the one. You'll get the second one eventually.

Carl


"Clint" <cneufeld@mysocks.shaw.ca> wrote in message
news:ns%mh.557918$R63.81715@pd7urf1no...
> Well, it must be time for a progress report...
>
> First, I tried the torch, followed by an extractor. I managed to snap the
> extractor off in the bolt. *sigh* I think my neighbor jinxed me on that
> one, cuz he warned me about it.
>
> I was able to cut off the bolt and get the remains of the extractor out,
> so no real harm done, anyway. I followed that up with a titanium coated
> bit, to try drilling it out. I think I should have used a beefier (or
> better) bit, as the bit busted off inside. *sigh again*
>
> So I picked up some better and bigger bits, and went at it again tonight.
> First, I had to remove the front of the Jeep, so I could get my drill in
> there. Turns out to be pretty easy (4 bolts, hidden behind the turn
> signals, in case you need to know), although I'm a little nervous about
> getting everything lined up again (assuming I get to put it back together
> some time). Gives me lots more room to work, anyway.
>
> I got the bottom bolt drilled out pretty quick, and I THINK I'll be ok
> with the threads. I'll have to wait and see on that one; the remains of
> the bolt showed just the very end threads to be touched by the drill bit..
> But the top bolt is still stuck tight, and the real problem now is the
> broken drill bit in it is keeping me from drilling it out.
>
> I saw someone else with a stuck tap in this same thread, and the
> suggestion was a carbide bit, an A/C drill, and a case of beer (or
> something like that). I think I'll pass on the beer (too many memories of
> New Year's Eve), but I'll break out my old corded drill and pick up a few
> more bits to try drilling it out.
>
> Hey, at least I won ONE fight tonight. :)
>
> Clint
>
> "Clint" <cneufeld@mysocks.shaw.ca> wrote in message
> news:UJCkh.535564$R63.397938@pd7urf1no...
>> So I'm elbows-deep in pulling out my radiator and water pump from my '88
>> Jeep Comanche (4.0l, if that matters), and as I figured was likely, two
>> bolt heads broke off. I've got pictures, if you care to see
>> (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're
>> broken off just under the head, so there's about 1/2" of threaded
>> material to grab, assuming that doesn't break off.
>>
>> What's the best method you've found to deal with these? Do any of them
>> work better than others? If I've got to drill a hole in them, how do you
>> get the hole started with an uneven surface like the broken off head?
>> Center-punch? That'll be fun to get in there with a hammer...
>>
>> So far, I figure I'm about 3 hours into the job, and I've got all the old
>> parts out. The old water pump actually looks like it's in good shaped
>> (vanes all there, looking pretty new), but it was leaking. There was no
>> sign of anything other than the paper gasket; should I be using the RTV
>> gasket gunk as well? Somehow, I've got to get into the block heater and
>> replace it as well. At least with the water pump out, I can see in there
>> a bit.
>>
>> Clint
>

Re: Best method for extracting bolts with broken off heads...
 

You have my symapthies on the various broken drills and extractors. I
have done that enough times that my current strategy is to do the "best
shot" the FIRST time. I know it is tempting to to try and work at an odd
angle to avoid taking out too many related parts but it is usually a
false start.

good luck.

Clint wrote:
> Well, it must be time for a progress report...
>
> First, I tried the torch, followed by an extractor. I managed to snap
> the extractor off in the bolt. *sigh* I think my neighbor jinxed me on
> that one, cuz he warned me about it.
>
> I was able to cut off the bolt and get the remains of the extractor out,
> so no real harm done, anyway. I followed that up with a titanium coated
> bit, to try drilling it out. I think I should have used a beefier (or
> better) bit, as the bit busted off inside. *sigh again*
>
> So I picked up some better and bigger bits, and went at it again
> tonight. First, I had to remove the front of the Jeep, so I could get my
> drill in there. Turns out to be pretty easy (4 bolts, hidden behind the
> turn signals, in case you need to know), although I'm a little nervous
> about getting everything lined up again (assuming I get to put it back
> together some time). Gives me lots more room to work, anyway.
>
> I got the bottom bolt drilled out pretty quick, and I THINK I'll be ok
> with the threads. I'll have to wait and see on that one; the remains of
> the bolt showed just the very end threads to be touched by the drill
> bit.. But the top bolt is still stuck tight, and the real problem now
> is the broken drill bit in it is keeping me from drilling it out.
>
> I saw someone else with a stuck tap in this same thread, and the
> suggestion was a carbide bit, an A/C drill, and a case of beer (or
> something like that). I think I'll pass on the beer (too many memories
> of New Year's Eve), but I'll break out my old corded drill and pick up a
> few more bits to try drilling it out.
>
> Hey, at least I won ONE fight tonight. :)
>
> Clint
>
> "Clint" <cneufeld@mysocks.shaw.ca> wrote in message
> news:UJCkh.535564$R63.397938@pd7urf1no...
>
>> So I'm elbows-deep in pulling out my radiator and water pump from my
>> '88 Jeep Comanche (4.0l, if that matters), and as I figured was
>> likely, two bolt heads broke off. I've got pictures, if you care to
>> see (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg).
>> They're broken off just under the head, so there's about 1/2" of
>> threaded material to grab, assuming that doesn't break off.
>>
>> What's the best method you've found to deal with these? Do any of
>> them work better than others? If I've got to drill a hole in them,
>> how do you get the hole started with an uneven surface like the broken
>> off head? Center-punch? That'll be fun to get in there with a hammer...
>>
>> So far, I figure I'm about 3 hours into the job, and I've got all the
>> old parts out. The old water pump actually looks like it's in good
>> shaped (vanes all there, looking pretty new), but it was leaking.
>> There was no sign of anything other than the paper gasket; should I be
>> using the RTV gasket gunk as well? Somehow, I've got to get into the
>> block heater and replace it as well. At least with the water pump
>> out, I can see in there a bit.
>>
>> Clint
>
>

Re: Best method for extracting bolts with broken off heads...
 

You have my symapthies on the various broken drills and extractors. I
have done that enough times that my current strategy is to do the "best
shot" the FIRST time. I know it is tempting to to try and work at an odd
angle to avoid taking out too many related parts but it is usually a
false start.

good luck.

Clint wrote:
> Well, it must be time for a progress report...
>
> First, I tried the torch, followed by an extractor. I managed to snap
> the extractor off in the bolt. *sigh* I think my neighbor jinxed me on
> that one, cuz he warned me about it.
>
> I was able to cut off the bolt and get the remains of the extractor out,
> so no real harm done, anyway. I followed that up with a titanium coated
> bit, to try drilling it out. I think I should have used a beefier (or
> better) bit, as the bit busted off inside. *sigh again*
>
> So I picked up some better and bigger bits, and went at it again
> tonight. First, I had to remove the front of the Jeep, so I could get my
> drill in there. Turns out to be pretty easy (4 bolts, hidden behind the
> turn signals, in case you need to know), although I'm a little nervous
> about getting everything lined up again (assuming I get to put it back
> together some time). Gives me lots more room to work, anyway.
>
> I got the bottom bolt drilled out pretty quick, and I THINK I'll be ok
> with the threads. I'll have to wait and see on that one; the remains of
> the bolt showed just the very end threads to be touched by the drill
> bit.. But the top bolt is still stuck tight, and the real problem now
> is the broken drill bit in it is keeping me from drilling it out.
>
> I saw someone else with a stuck tap in this same thread, and the
> suggestion was a carbide bit, an A/C drill, and a case of beer (or
> something like that). I think I'll pass on the beer (too many memories
> of New Year's Eve), but I'll break out my old corded drill and pick up a
> few more bits to try drilling it out.
>
> Hey, at least I won ONE fight tonight. :)
>
> Clint
>
> "Clint" <cneufeld@mysocks.shaw.ca> wrote in message
> news:UJCkh.535564$R63.397938@pd7urf1no...
>
>> So I'm elbows-deep in pulling out my radiator and water pump from my
>> '88 Jeep Comanche (4.0l, if that matters), and as I figured was
>> likely, two bolt heads broke off. I've got pictures, if you care to
>> see (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg).
>> They're broken off just under the head, so there's about 1/2" of
>> threaded material to grab, assuming that doesn't break off.
>>
>> What's the best method you've found to deal with these? Do any of
>> them work better than others? If I've got to drill a hole in them,
>> how do you get the hole started with an uneven surface like the broken
>> off head? Center-punch? That'll be fun to get in there with a hammer...
>>
>> So far, I figure I'm about 3 hours into the job, and I've got all the
>> old parts out. The old water pump actually looks like it's in good
>> shaped (vanes all there, looking pretty new), but it was leaking.
>> There was no sign of anything other than the paper gasket; should I be
>> using the RTV gasket gunk as well? Somehow, I've got to get into the
>> block heater and replace it as well. At least with the water pump
>> out, I can see in there a bit.
>>
>> Clint
>
>

Re: Best method for extracting bolts with broken off heads...
 

You have my symapthies on the various broken drills and extractors. I
have done that enough times that my current strategy is to do the "best
shot" the FIRST time. I know it is tempting to to try and work at an odd
angle to avoid taking out too many related parts but it is usually a
false start.

good luck.

Clint wrote:
> Well, it must be time for a progress report...
>
> First, I tried the torch, followed by an extractor. I managed to snap
> the extractor off in the bolt. *sigh* I think my neighbor jinxed me on
> that one, cuz he warned me about it.
>
> I was able to cut off the bolt and get the remains of the extractor out,
> so no real harm done, anyway. I followed that up with a titanium coated
> bit, to try drilling it out. I think I should have used a beefier (or
> better) bit, as the bit busted off inside. *sigh again*
>
> So I picked up some better and bigger bits, and went at it again
> tonight. First, I had to remove the front of the Jeep, so I could get my
> drill in there. Turns out to be pretty easy (4 bolts, hidden behind the
> turn signals, in case you need to know), although I'm a little nervous
> about getting everything lined up again (assuming I get to put it back
> together some time). Gives me lots more room to work, anyway.
>
> I got the bottom bolt drilled out pretty quick, and I THINK I'll be ok
> with the threads. I'll have to wait and see on that one; the remains of
> the bolt showed just the very end threads to be touched by the drill
> bit.. But the top bolt is still stuck tight, and the real problem now
> is the broken drill bit in it is keeping me from drilling it out.
>
> I saw someone else with a stuck tap in this same thread, and the
> suggestion was a carbide bit, an A/C drill, and a case of beer (or
> something like that). I think I'll pass on the beer (too many memories
> of New Year's Eve), but I'll break out my old corded drill and pick up a
> few more bits to try drilling it out.
>
> Hey, at least I won ONE fight tonight. :)
>
> Clint
>
> "Clint" <cneufeld@mysocks.shaw.ca> wrote in message
> news:UJCkh.535564$R63.397938@pd7urf1no...
>
>> So I'm elbows-deep in pulling out my radiator and water pump from my
>> '88 Jeep Comanche (4.0l, if that matters), and as I figured was
>> likely, two bolt heads broke off. I've got pictures, if you care to
>> see (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg).
>> They're broken off just under the head, so there's about 1/2" of
>> threaded material to grab, assuming that doesn't break off.
>>
>> What's the best method you've found to deal with these? Do any of
>> them work better than others? If I've got to drill a hole in them,
>> how do you get the hole started with an uneven surface like the broken
>> off head? Center-punch? That'll be fun to get in there with a hammer...
>>
>> So far, I figure I'm about 3 hours into the job, and I've got all the
>> old parts out. The old water pump actually looks like it's in good
>> shaped (vanes all there, looking pretty new), but it was leaking.
>> There was no sign of anything other than the paper gasket; should I be
>> using the RTV gasket gunk as well? Somehow, I've got to get into the
>> block heater and replace it as well. At least with the water pump
>> out, I can see in there a bit.
>>
>> Clint
>
>

Re: Best method for extracting bolts with broken off heads...
 

I am surprised no one has suggested he gets it blown out with a torch...

I know folks that swear they can blow the steel bolts out of the cast
with a cutting torch without damaging the threads in the cast.

Just a though.....

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

RoyJ wrote:
>
> You have my symapthies on the various broken drills and extractors. I
> have done that enough times that my current strategy is to do the "best
> shot" the FIRST time. I know it is tempting to to try and work at an odd
> angle to avoid taking out too many related parts but it is usually a
> false start.
>
> good luck.
>
> Clint wrote:
> > Well, it must be time for a progress report...
> >
> > First, I tried the torch, followed by an extractor. I managed to snap
> > the extractor off in the bolt. *sigh* I think my neighbor jinxed me on
> > that one, cuz he warned me about it.
> >
> > I was able to cut off the bolt and get the remains of the extractor out,
> > so no real harm done, anyway. I followed that up with a titanium coated
> > bit, to try drilling it out. I think I should have used a beefier (or
> > better) bit, as the bit busted off inside. *sigh again*
> >
> > So I picked up some better and bigger bits, and went at it again
> > tonight. First, I had to remove the front of the Jeep, so I could get my
> > drill in there. Turns out to be pretty easy (4 bolts, hidden behind the
> > turn signals, in case you need to know), although I'm a little nervous
> > about getting everything lined up again (assuming I get to put it back
> > together some time). Gives me lots more room to work, anyway.
> >
> > I got the bottom bolt drilled out pretty quick, and I THINK I'll be ok
> > with the threads. I'll have to wait and see on that one; the remains of
> > the bolt showed just the very end threads to be touched by the drill
> > bit.. But the top bolt is still stuck tight, and the real problem now
> > is the broken drill bit in it is keeping me from drilling it out.
> >
> > I saw someone else with a stuck tap in this same thread, and the
> > suggestion was a carbide bit, an A/C drill, and a case of beer (or
> > something like that). I think I'll pass on the beer (too many memories
> > of New Year's Eve), but I'll break out my old corded drill and pick up a
> > few more bits to try drilling it out.
> >
> > Hey, at least I won ONE fight tonight. :)
> >
> > Clint
> >
> > "Clint" <cneufeld@mysocks.shaw.ca> wrote in message
> > news:UJCkh.535564$R63.397938@pd7urf1no...
> >
> >> So I'm elbows-deep in pulling out my radiator and water pump from my
> >> '88 Jeep Comanche (4.0l, if that matters), and as I figured was
> >> likely, two bolt heads broke off. I've got pictures, if you care to
> >> see (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg).
> >> They're broken off just under the head, so there's about 1/2" of
> >> threaded material to grab, assuming that doesn't break off.
> >>
> >> What's the best method you've found to deal with these? Do any of
> >> them work better than others? If I've got to drill a hole in them,
> >> how do you get the hole started with an uneven surface like the broken
> >> off head? Center-punch? That'll be fun to get in there with a hammer...
> >>
> >> So far, I figure I'm about 3 hours into the job, and I've got all the
> >> old parts out. The old water pump actually looks like it's in good
> >> shaped (vanes all there, looking pretty new), but it was leaking.
> >> There was no sign of anything other than the paper gasket; should I be
> >> using the RTV gasket gunk as well? Somehow, I've got to get into the
> >> block heater and replace it as well. At least with the water pump
> >> out, I can see in there a bit.
> >>
> >> Clint
> >
> >

Re: Best method for extracting bolts with broken off heads...
 

I am surprised no one has suggested he gets it blown out with a torch...

I know folks that swear they can blow the steel bolts out of the cast
with a cutting torch without damaging the threads in the cast.

Just a though.....

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

RoyJ wrote:
>
> You have my symapthies on the various broken drills and extractors. I
> have done that enough times that my current strategy is to do the "best
> shot" the FIRST time. I know it is tempting to to try and work at an odd
> angle to avoid taking out too many related parts but it is usually a
> false start.
>
> good luck.
>
> Clint wrote:
> > Well, it must be time for a progress report...
> >
> > First, I tried the torch, followed by an extractor. I managed to snap
> > the extractor off in the bolt. *sigh* I think my neighbor jinxed me on
> > that one, cuz he warned me about it.
> >
> > I was able to cut off the bolt and get the remains of the extractor out,
> > so no real harm done, anyway. I followed that up with a titanium coated
> > bit, to try drilling it out. I think I should have used a beefier (or
> > better) bit, as the bit busted off inside. *sigh again*
> >
> > So I picked up some better and bigger bits, and went at it again
> > tonight. First, I had to remove the front of the Jeep, so I could get my
> > drill in there. Turns out to be pretty easy (4 bolts, hidden behind the
> > turn signals, in case you need to know), although I'm a little nervous
> > about getting everything lined up again (assuming I get to put it back
> > together some time). Gives me lots more room to work, anyway.
> >
> > I got the bottom bolt drilled out pretty quick, and I THINK I'll be ok
> > with the threads. I'll have to wait and see on that one; the remains of
> > the bolt showed just the very end threads to be touched by the drill
> > bit.. But the top bolt is still stuck tight, and the real problem now
> > is the broken drill bit in it is keeping me from drilling it out.
> >
> > I saw someone else with a stuck tap in this same thread, and the
> > suggestion was a carbide bit, an A/C drill, and a case of beer (or
> > something like that). I think I'll pass on the beer (too many memories
> > of New Year's Eve), but I'll break out my old corded drill and pick up a
> > few more bits to try drilling it out.
> >
> > Hey, at least I won ONE fight tonight. :)
> >
> > Clint
> >
> > "Clint" <cneufeld@mysocks.shaw.ca> wrote in message
> > news:UJCkh.535564$R63.397938@pd7urf1no...
> >
> >> So I'm elbows-deep in pulling out my radiator and water pump from my
> >> '88 Jeep Comanche (4.0l, if that matters), and as I figured was
> >> likely, two bolt heads broke off. I've got pictures, if you care to
> >> see (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg).
> >> They're broken off just under the head, so there's about 1/2" of
> >> threaded material to grab, assuming that doesn't break off.
> >>
> >> What's the best method you've found to deal with these? Do any of
> >> them work better than others? If I've got to drill a hole in them,
> >> how do you get the hole started with an uneven surface like the broken
> >> off head? Center-punch? That'll be fun to get in there with a hammer...
> >>
> >> So far, I figure I'm about 3 hours into the job, and I've got all the
> >> old parts out. The old water pump actually looks like it's in good
> >> shaped (vanes all there, looking pretty new), but it was leaking.
> >> There was no sign of anything other than the paper gasket; should I be
> >> using the RTV gasket gunk as well? Somehow, I've got to get into the
> >> block heater and replace it as well. At least with the water pump
> >> out, I can see in there a bit.
> >>
> >> Clint
> >
> >