Broken bolt headaches!

[In The Ten Ring]

I removed the gas tank last July but I twisted a bolt head off when removing it. There were 7 bolts that hold it to the rear of the cab's floor plus the seat belt bolts....anyway....I lost one head.

So today I centerpunched (dead center too!), drilled, then when I tried the extractor, BOOM, the extractor breaks off! So I'm thinking it's time to super glue on a nut, tack weld that to the broken bolt, then wrench it out.

Am I thinking clearly here?

THE GAS TANK HAS BEEN REMOVED.

[Lattimer]

Originally Posted by In The Ten Ring

So I twisted a bolt head off when removing the gas tank. There are 7 bolts that hold it to the rear of the cab's floor plus the seat belt bolts....anyway....I lost one head.

So today I centerpunched (dead center too!), drilled, then when I tried the extractor, BOOM, the extractor breaks off! So I'm thinking it's time to super glue on a nut, tack weld that to the broken bolt, then wrench it out.

Am I thinking clearly here?

I have had the best luck welding a nut to the broken bolt like you are describing. Sometimes I've to had to weld it back on 3-4 times before I won.

I don't think I have ever had an extractor work yet.

[72 K20]

I've had good luck with welding a flat washer on to the broken bolt first ,and then weld a nut to the washer. It seems to be easier to get the washer welded on than welding through the nut

[bigsnookmaster]

I would try the welded nut trick, but wouldn't worry too much if you cant get it. You have 6 more bolts holding it on. 1 wont make a real difference. .02

[In The Ten Ring]

You are right and I've been thinking about it. There are indeed 6 more bolts to hold the gas tank in and there are also the 2 seltbelt bolts. I'm just being OCD again.

[ajsfirehawk]

Can you get a cutting blade on a die grinder in there? Cut a slot, liquid wrench overnight, and then hit it with the impact style screw driver. The ones you smack with a hammer and it gives you an 1/8th turn when you smack it. Can break them loose so you can take it the rest of the way with a standard screw driver

[motorcritter]

The impact driver has performed many small miracles for me, the improvised screw slot is a trick my uncle taught me as a kid. I think the heat of welding the nut on the broken fastener helps to loosen it up enough to get it out. I've never broken an extractor yet, if it looks like a tough one, and there's no flammables in the area, drill it for the extractor, a shot of flame wrench, and happiness prevails. Squirting some penetrant in it while it's hot can help, too.
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[In The Ten Ring]

I'll update my original post with a pic tomorrow so you guys can get a better feel for what I'm up against.

[boynton]

PB blaster and any of the suggested removal tricks described. They all work. Also get a longer drill bit and drill deeper into the bolt. It will relieve the pressure.
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[bigmac73]

remove the rest of the bolts and get the tank out of the way , to give you more room
i would drill straight through it with a small bit then go one size smaller than bolt diameter.
soak it again, and try another easy out or i have had luck with running a tap though it and grabbing it

[cdowns]

for those type jobs i really love my reverse twist drill bits as they help back the bolt out while you r drilling it and that plus the heat that is generated it sometimes all u need to get a broken bolt out

[volksworld]

the first rule of extractors is that if the head snapped off the bolt while loosening it the extractor(which is smaller in diameter and brittle cause its hardened to bite into the bolt) will also break...extractors are for things you snapped while overtightening or that broke off in an accident and aren't rusted in....if you cant use a torch(gas tank),drill it and retap /helicoil and forget you own an extractor set....the best way to remove a broken bolt is to not break it in the first place...lots of penetrant/heat/patience

[In The Ten Ring]

Since there is an extractor head stuck dead center into this broken bolt, no one is going to be drilling it out! :-( I guess it's up to the welder now.

Thanks for the advice on how to use extractors.....I certainly learned with this little incident! :-P

I'm been wanting a set of reverse drill bits...I'll go on and get a set now.

[cdowns]

a center punch and a hammer can disintigrate a busted easy out