Broken easy out - nightmare scenario

[armalites]

Is that not a seizure?

Jinx
I had actually typed that but didn't post it, my thoughts exactly

The one time I've had success with an easy out was in my youth, was reversing pretty fast then grabbing 1st in my Astra, often sheared the bolt in the gearbox mount, it wasn't seized as I replaced the week before

 

[123hotchef]

Drill a hole then bang in the extractor which has small splines on and slide the nut type thing onto it and turn with a spanner.

I thought so those extractors must be hardened then,

 

[Bill Edwards]

I thought so those extractors must be hardened then,

I can't think of any extractor that isn't hardened as not only are they all designed to 'bite' into the material but also to do more than one job before going dull.
Trouble is, because they're so hard if you break one flush or below the surface so you can't get hold of it your options are limited as you cannot drill them with ordinary drill bits, they're too hard.

 

[outofthefire]

Well done
I once worked with a bloke who could get anything out, the one thing he taught me was take your time and consider all the options.
I rarely use Easy outs but have had lots of success with Ridgid extractors.
https://www.powertoolsdirect.com/ri...theY49d5cZyLrWY7jPUG8MWB9Z0sbGlYNmBoCgojw_wcB

I've had success with a borrowed set of them but they were branded as snap on. I got a seized bleed nipple out with them, I was sure it was going to snap but the nipple gave first. Because they're parallel they don't add any outwards pressure to the seized part unlike tapered easy outs which add outward force with every turn making the job worse the more pressure is applied.

 

[500e]

Rigid are the way if you have to use screw extractors

 

[zzr1200]

Well done
I once worked with a bloke who could get anything out, the one thing he taught me was take your time and consider all the options.
I rarely use Easy outs but have had lots of success with Ridgid extractors.
https://www.powertoolsdirect.com/ri...theY49d5cZyLrWY7jPUG8MWB9Z0sbGlYNmBoCgojw_wcB

Theses are the best type of easy out available sold under many names, I have the remains of a Skye's Picavant set that I was issued with about 35 years ago and a new-ish Snapon/Blue Point set.

Also drill the hole all the through the broken bolt if possible as the splined shaft can be a real bitch to remove if its in a blind hole...

 

[Pete.]

Theses are the best type of easy out available sold under many names, I have the remains of a Skye's Picavant set that I was issued with about 35 years ago and a new-ish Snapon/Blue Point set.

Also drill the hole all the through the broken bolt if possible as the splined shaft can be a real bitch to remove if its in a blind hole...

Bit on the heavy side for a hand tool though....

Lightweight construction at just 560 Kgs

 

[nickk]

I've got a set of left handed drill bits very short,which have a threaded shank,you wind a tapered split collet down into the stub so if the drill bit hasn't moved it the driven in collet has spanner flats to give a purchase surface to grip ,not sure wether the tapered collet causes expanding of the broken thread as the drills & collets are sized according to the diameter of bolt your extracting.cant recall the name of them except they're American,& I've had several successes with them.occasionally the l/h drill on its own has shifted the bolt.

 

[wristpin]

Well done
I once worked with a bloke who could get anything out, the one thing he taught me was take your time and consider all the options.
I rarely use Easy outs but have had lots of success with Ridgid extractors.
https://www.powertoolsdirect.com/ri...theY49d5cZyLrWY7jPUG8MWB9Z0sbGlYNmBoCgojw_wcB

Same set is available from Snap-on / Blue Point.

 

[wristpin]

The new plugs are getting fitted with a small smear of copper grease on the threads and very lightly tightened as I never want to have to do this again.

.

Bear in mind that the "seizure" is the product of electrolytic corrosion between dissimilar metals and that by using copper anti seize you are adding a third metal to the equation. Graphite grease may be a better option.

 

[graffian]

Same set is available from Snap-on / Blue Point.

I got the stud exctractors[easy outs] out to remove a bolt from something on the snap-on mans kneeler.
He laughed and made some comment and was then amazed as I pulled the broken item out with it; he
paid me with a set of the snap-on fluted extractors. The fluted extractors are far better, but looking at my
set they snap-off quite well.

 

[Mee]

I've got a set of left handed drill bits very short,which have a threaded shank,you wind a tapered split collet down into the stub so if the drill bit hasn't moved it the driven in collet has spanner flats to give a purchase surface to grip ,not sure wether the tapered collet causes expanding of the broken thread as the drills & collets are sized according to the diameter of bolt your extracting.cant recall the name of them except they're American,& I've had several successes with them.occasionally the l/h drill on its own has shifted the bolt.

I have a number of left hand drill bits and I find on most occasions they fetch a broken stud out on their own.

 

[ms08]

To clean your threads - bring the piston up to TDC before starting work and then use a vacuum should get most/all of the swarf out.

 

[Parm]

Several years ago I had the same issue with a lower exhaust manifold bolt on my yank tank. Easy out snapped in the collector, as did a cobalt drill bit. After much swearing and head scratching it was slowly drilled out clear using a tipped masonry drill all whil on my back under the car

Easy outs are banned at home !!!

 

[500e]

Heard that before Parm never had any luck, only ever had the Ridged extractors never broken one though.
Have a set of these as well

for screws with chewed heads

 

[Mr shiney]

Heard that before Parm never had any luck, only ever had the Ridged extractors never broken one though.
Have a set of these as well

for screws with chewed heads

Me too and they have proven to be a lifesaver many times!!

 

[Crater Creator]

To clean your threads - bring the piston up to TDC before starting work and then use a vacuum should get most/all of the swarf out.

That is what I've done today. The 8mm threads tapped out again nicely, I filled the flutes in the tap with calcium based grease, which is nice and thick, a bit like soft lard, I reckon all the swarf came back out stuck to the grease on the tap, but the vacuum may have picked up some stragglers.
Job done. Thanks for the suggestions and comments.

Edited to add pics....

 

[123hotchef]

Heard that before Parm never had any luck, only ever had the Ridged extractors never broken one though.
Have a set of these as well

for screws with chewed heads

do these work i have some that dont seem to do anything

 

[Crater Creator]

Bear in mind that the "seizure" is the product of electrolytic corrosion between dissimilar metals and that by using copper anti seize you are adding a third metal to the equation. Graphite grease may be a better option.

Yeah I have heard that, but I've never had anything I've copper-greased seize up. I think it got ingrained to me after many years offshore where it got lathered over everything and anything and seemed to do a good job. That and denso-tape - yuk.

 

[Mee]

Copper grease coats the material with a soft metal, namely copper.