major engine broken bolt

Discussion in 'GS Boxers' started by mqo233, Nov 23, 2012.

  1. mqo233

    mqo233 Been here awhile

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    Jan 2, 2006
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    459
    Location:
    Lafayette, Louisiana
    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
    #1
  2. onewheelwunder

    onewheelwunder are we there yet?

    Joined:
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    APPLY heat! It may have red thread locker on it. Heat guns work best, torch in a pinch
    #2
  3. def

    def Ginger th wonder dog

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    If heat fails, EDM would be my next approach. I believe there are some portable EDM services out there.
    #3
  4. mqo233

    mqo233 Been here awhile

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    what is a EDM device
    #4
  5. mqo233

    mqo233 Been here awhile

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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
    #5
  6. JRP

    JRP Old guy

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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. :lol3
    #6
  7. ragtoplvr

    ragtoplvr Long timer

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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!

    Rod
    #7
  8. def

    def Ginger th wonder dog

    Joined:
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    #8
  9. Pukmeister

    Pukmeister Adventurer

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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.
    #9
  10. schlim66

    schlim66 Lone Rider

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    http://youtu.be/XfYXelZ4IaY

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


    Schlim66
    #10
  11. lhendrik

    lhendrik Truffle Rustler

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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.
    #11
  12. def

    def Ginger th wonder dog

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    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
    #12
  13. Lujo

    Lujo Long timer

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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.
    #13
  14. mqo233

    mqo233 Been here awhile

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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
    #14
  15. Lujo

    Lujo Long timer

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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.)
    #15
  16. mqo233

    mqo233 Been here awhile

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    I contacted the people in Broussard, with the machine, really nice guys, they need the engine apart, to portable machines, he does not have, and with the portable, it sends current through everything so all electronics have to be removed, if we have to break the cases to get the bolt out, he can help,

    I contacted Dremal and they are sending 2 of each of all of the strongest bits they have,

    any other ideas?

    we may have a motorcycle for sale,

    James
    #16
  17. def

    def Ginger th wonder dog

    Joined:
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    Contact a local machinist at a professional machine shop. These guys usually have had plenty of experience removing broken stuff.
    #17
  18. mqo233

    mqo233 Been here awhile

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    well, we got the broken bolt out, and that is all good, it took some time for the drimel tool bits to cut the bolt out, and then it took some time before the helicore kit came in, just finding someone who would sell the complete kit was difficult, so, if anyone has a broken bolt, call me,

    meanwhile we were able to determine that the problem is the transmission, one bearing came loose and really distroyed everything else, so, one new transmission from the father land, is on order,

    wonderful,

    happy new year

    James
    #18