Removing a difficult broken bolt
The trick is to grind away the bolt and Ezy-out bolt remover using a small ‘pencil die’ grinder. The Ezy-out cannot be drilled as it is too hard.
The only way to remove it is grind your way through it.
It is a slow process but the only way to get it out.
Step-by-step:
Step 1:
Firstly make a centre punch mark in the centre of the bolt and drill a hole up the middle of the bolt.
Drill it all the way through, being careful not to drill out the side of the bolt and into the thread.
Step 2:
Spray plenty of lubricant up the inside of the bolt and let it soak for a few minutes to lubricate the thread and make the bolt easier to remove.
Step 3:
Fit an Ezy-out into the broken bolt and try to remove the bolt. Don’t be too heavy handed or the Ezy-out will snap.
Step 4:
If the Ezy-out does snap, get out the pencil die grinder and, using a small tip, and plenty of WD40 to lubricate the tip, grind your way through the broken Ezy-out. The Ezy-out is too hard to drill so the only way through it is to grind it out. This can be a slow, delicate process.
(Once the Ezy-out has snapped, do not try to drill it out as it is too hard and can snap the drill bit. The last thing you need on top of a broken Ezy-out stuck in the bolt is a snapped drill but as well.)
Step 5:
Once you have ground your way through the Ezy-out, continue to grind out most of the bolt and then, using a tap and WD40, recut the thread to remove any of the remnants of the old bolt.
Then replace the bolt and tighten back into place.
TIP:
Whenever drilling or tapping threads always use something such as WD40 for lubricant and wear eye protection.
