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:

stp1

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:

stp2

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:

stp3

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:

stp4

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:

stp5

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.