Drill bit broke in hole..Now what?

[tatu]

Is this a cover on a cover? ie can the whole part be removed? If so then have a ring around your local engineering shops and find one that does spark eroding.
Spark eroding has never failed for me.

 

[chuck hahn]

Cover bolt on the TX..Its just a cover that goes over the points and stator covers. The stator has its onw seperate cover and the gasket seals the cover because its oil cooled like our GSs are. The outer cover is purely a decorative cover which hides everything behind it. I have also thought of just grinding the shank thats left on the head back a bit and just glueing it in the hole so it "looks like " theres a bolt in there. But ideally i would like to get the stud out and do it right. 6 of one and half dozen of another i guess.

 

[twotimeGSr]

Seems like you could use a tool like a dremel with a diamond point tip and slowly grind a slot in it and maybe get it out with a flat head screw driver/impact driver.. Might have to mist with water to keep the tip cool.

 

[twotimeGSr]

Is this a cover on a cover? ie can the whole part be removed? If so then have a ring around your local engineering shops and find one that does spark eroding.
Spark eroding has never failed for me.

What is spark eroding?

 

[tatu]

You have another alternative or two, I have a set of these at home but I've not had to use them yet, I'm told the result is spectacular.
http://www.cromwell.co.uk/KEN1541050K
Being solid Carbide they are very heavy for their size.
Another way is to grind a proper sharp cutting edge on a masonry drill, that will get it too.

twotimeGSr.. Spark eroding is essentially drilling but using a high current spark to erode the metal away, the part is clamped down and immersed in oil andthe spark is started in the middle and worked outwards as the unwanted metal is eroded away, once the core is gone the remaining thread that is left is unwound just like a helicoil leaving the original thread untouched. Garanteed positive result.

 

[portdave]

I do have some real small bits Dave. Some relief and work it free may be the trick. The thing is that the cover really doesnt hold back oil or anything so if it was at the bottom out of sight or whatever i wouldnt give a crap one way or the other, but its right at the top and one missing will bug the hell out of me to no end.

Give the smallest drill bit a go. Even if you have to re-tap it afterwards since it is just for a cover you should be good to go. Good luck.

 

[1_v8_merc]

.45 magnum?

 

[chuck hahn]

I tried a small bit to go along bside the broken off bit..all that did was dull the small bit almost instantly. Broke piece is still down in there. Anyhting eklse short of the 45 MAG ???

 

[JJ]

What is spark eroding?

AKA EDM... Electric Discharge Machining. It burns the broken off bolt/screw out of the hole so that threads can be cleaned out and re-tapped.

 

[hampshirehog]

Can you get alongside it with a torx bit? They grab pretty well and the busted drill won't be in there very tight.

 

[Guest]

when welding onto bolts that are broken off down in the hole I have used paper straws or a rolled up piece of paper as a rod guide so the rod doesn't touch the sides of the hole. then just weld your way back up the hole, let the paper burn.
For some reason , the weld doesn't stick to the sides of the hole, even in steel.

 

[chuck hahn]

The weld wont stick to the aluminum case either..just worried about melting the threads.

 

[Planecrazy]

When welding onto bolts that are broken off down in the hole I have used paper straws or a rolled up piece of paper as a rod guide so the rod doesn't touch the sides of the hole. then just weld your way back up the hole, let the paper burn.
For some reason , the weld doesn't stick to the sides of the hole, even in steel.

Clever idea ... I like that! Bet you could build up the weld enough with the MIG to grab it with a pliers and get the broken bit out!

Watching with interest to see if this works!

Regards,

 

[chuck hahn]

WSelding onto it will heat the crap out of it too...which is good to crack the bonding oxidation. I will try it probably Tuesday if i get the day off.