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Old 02-07-2013, 04:20 PM   #1
as350pilot
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Default ?? How to remove sheared off bolt on front roof support

I need some advice on how to drill out, remove, etc... a sheared off bolt for the front roof support. I have tried several types of drill bits, "multi-purpose bits, bits for tap & die sets..., but I have not been able to successfully drill through the bolt. I use cutting oil as well as WD-40 type lubricants.

Any ideas?
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Old 02-07-2013, 07:01 PM   #2
kab69440
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Default Re: ?? How to remove sheared off bolt on front roof support

Is any of it protruding through the other side? I heated the one that broke and then screwed it out ( from the frame side) with a stud puller.
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Old 02-07-2013, 07:46 PM   #3
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Default Re: ?? How to remove sheared off bolt on front roof support

If there is any of the broken stud protruding outward, weld a nut onto the broken stud, let it cool and then try to back it out with a wrench on the nut. You may also want to go to your local auto parts strore and get an "easy out" they usually come with a hardened drill bit. Drive the tapered E-Z out into the drilled hole. The E-Z outs turn left handed to remove what remains of the broken bolt. Good luck. PBB
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Old 02-07-2013, 08:33 PM   #4
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Default Re: ?? How to remove sheared off bolt on front roof support

Drill it out and put a bolt and nut back in

They rust unmercifully sometimes.
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Old 02-07-2013, 09:29 PM   #5
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Default Re: ?? How to remove sheared off bolt on front roof support

Quote:
Originally Posted by scottyb View Post
Drill it out and put a bolt and nut back in

They rust unmercifully sometimes.
Agreed. One of mine actually tightened up and froze as I was REMOVING it. Loosey, loosey, loosey, uh-oh. Snapped right off in the threads.

Spent an hour at least, and 2 drill bits getting the first small diameter hole in that bolt, then it was easy to upsize the bits and keep drilling larger diameter holes until the job was done. An Easy-Out was not gonna work here.
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Old 02-07-2013, 11:23 PM   #6
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Default Re: ?? How to remove sheared off bolt on front roof support

Can't tell you how many times I've been here! Wasted a lot of time trying to save the threads .. and for what? The finished result is the same.
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Old 02-08-2013, 07:01 AM   #7
as350pilot
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Default Re: ?? How to remove sheared off bolt on front roof support

Quote:
Originally Posted by scottyb View Post
Drill it out and put a bolt and nut back in

They rust unmercifully sometimes.
That's my goal right now, but I have been drilling for a total of about two hours right now. I don't seem to be getting any where. Maybe I am just not patient enough......
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Old 02-08-2013, 09:45 AM   #8
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Default Re: ?? How to remove sheared off bolt on front roof support

It's a 10 minute job with the right drill bits?
I would guess your bit is for wood? Get a couple of good quality steel bits. 1/4 for the pilot hole and 21/64 for the final hole the 5/16ths bolt will fit through.
Use a slow 1/2" drill for best results.
What you don't want to do is spin the drill too fast and heat it up = ruining the temper.
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Old 02-08-2013, 10:50 AM   #9
essness
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Default Re: ?? How to remove sheared off bolt on front roof support

I like a cobalt bit with large flutes and 135 degree split point in a mechanics length and flats on the shaft.
The drill bit will make all the difference in this process.

Cobalt = extremely hard and dissapates heat well.
Large flutes = clears easy, dissapates heat better.
135 degree split point helps center and keep centered.
Mechanics length = shorter bit less likely to break with high feed.
Flats on shaft = keeps it from spinning in the chuck.

You want to run it at "slow speed, high feed". Works everytime and only takes about 15 mins to drill the pilot hole.
I've always been able to get the broken bolt out with an ez-out but I've been prepared to drill it completely out and re-tap if needed.
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Old 02-08-2013, 11:23 AM   #10
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Default Re: ?? How to remove sheared off bolt on front roof support

Good post Scot, there is nothing that cuts so well as the proper NEW bit.
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