Broken off bolt

Taylor1595 · 07-30-2013, 01:41 PM

Ok, I'm doing a build on an 01 txt and broke the bottom front roof strut bolt off in the frame. I have tried for a few hours to drill the bolt out and have maybe made it an inch at the most. I've never drilled metal this hard. I've ruined probably ten bits and am about to go buy a cobalt bit to try. Anybody else ran into this an any solution other than just keep drilling?

yurtle · 07-30-2013, 01:50 PM

Stud extractor (ez-out).

Taylor1595 · 07-30-2013, 02:03 PM

Already messed up and got off center and destroyed threads so that won't work I'm afraid.

gornoman · 07-30-2013, 02:18 PM

It's a biotch, that's for sure. Keep drilling, you'll get through eventually. A good drill bit makes the task easier, just keep in mind you are drilling through over one inch of hard metal.

kgsc · 07-30-2013, 02:57 PM

just a thought but did you look under the fender to see if any of it is sticking through the threads ?? If so, shoot some kroil or PB to it and get out the vise grips

Sir Nuke · 07-30-2013, 03:13 PM

and once you get it out, seeing as how you said you got off-center. insted if using a larger bolt to go back with....put a Helicoil in it to restore the hole.....just depends on how much off-center you got.

kgsc · 07-30-2013, 03:17 PM

I believe it is a 5/16 bolt in there. Last one that did this to me I just drilled all the way through and replaced it with a longer bolt and a nut. Not original but it works..

gornoman · 07-30-2013, 04:22 PM

Those front roof hoops are a great place to be using stainless steel hardware.

DOOmsman · 07-30-2013, 05:05 PM

Never seize is your best friend.

beachin · 07-30-2013, 05:16 PM

Just did this 2 weeks ago - keep drilling! Start with a smaller bit then after that is through ream it with a bigger one.

It worked so well that I wound up reaming the other 3 and using bolts (stainless) with lock washers.

Figure I can always use a grinder to cut the heads off of those & push them through if need be down the road.

07-30-2013, 01:41 PM	#1
Taylor1595 Not Yet Wild Join Date: Jul 2013 Posts: 47	Broken off bolt Ok, I'm doing a build on an 01 txt and broke the bottom front roof strut bolt off in the frame. I have tried for a few hours to drill the bolt out and have maybe made it an inch at the most. I've never drilled metal this hard. I've ruined probably ten bits and am about to go buy a cobalt bit to try. Anybody else ran into this an any solution other than just keep drilling?
Taylor1595 Not Yet Wild Join Date: Jul 2013 Posts: 47

07-30-2013, 01:50 PM	#2
yurtle Gone Mad Join Date: Oct 2009 Location: Buford, GA Posts: 8,988	Re: Broken off bolt Stud extractor (ez-out).

07-30-2013, 02:03 PM	#3
Taylor1595 Not Yet Wild Join Date: Jul 2013 Posts: 47	Re: Broken off bolt Already messed up and got off center and destroyed threads so that won't work I'm afraid.
Taylor1595 Not Yet Wild Join Date: Jul 2013 Posts: 47

07-30-2013, 02:18 PM	#4
gornoman Stay thirsty my friends! Join Date: Jan 2007 Location: Suburban Chicago Posts: 24,284	Re: Broken off bolt It's a biotch, that's for sure. Keep drilling, you'll get through eventually. A good drill bit makes the task easier, just keep in mind you are drilling through over one inch of hard metal.

07-30-2013, 02:57 PM	#5
kgsc Gone Wild Join Date: Dec 2009 Location: Aiken, SC Posts: 13,141	Re: Broken off bolt just a thought but did you look under the fender to see if any of it is sticking through the threads ?? If so, shoot some kroil or PB to it and get out the vise grips

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07-30-2013, 03:13 PM	#6
Sir Nuke Master of All Things Join Date: May 2013 Location: West Columbia, Texas Posts: 17,976	Re: Broken off bolt and once you get it out, seeing as how you said you got off-center. insted if using a larger bolt to go back with....put a Helicoil in it to restore the hole.....just depends on how much off-center you got.

07-30-2013, 03:17 PM	#7
kgsc Gone Wild Join Date: Dec 2009 Location: Aiken, SC Posts: 13,141	Re: Broken off bolt I believe it is a 5/16 bolt in there. Last one that did this to me I just drilled all the way through and replaced it with a longer bolt and a nut. Not original but it works..

07-30-2013, 04:22 PM	#8
gornoman Stay thirsty my friends! Join Date: Jan 2007 Location: Suburban Chicago Posts: 24,284	Re: Broken off bolt Those front roof hoops are a great place to be using stainless steel hardware.

07-30-2013, 05:05 PM	#9
DOOmsman Gone Wild Join Date: Jul 2008 Location: Reddick IL Posts: 11,220	Re: Broken off bolt Never seize is your best friend.

07-30-2013, 05:16 PM	#10
beachin Not Yet Wild Join Date: May 2013 Location: San Diego, CA Area Posts: 30	Re: Broken off bolt Just did this 2 weeks ago - keep drilling! Start with a smaller bit then after that is through ream it with a bigger one. It worked so well that I wound up reaming the other 3 and using bolts (stainless) with lock washers. Figure I can always use a grinder to cut the heads off of those & push them through if need be down the road.

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