Drilling out Easy Out?

[Guest]

I have broken an easyout extractor inside the intake boot bolt on my GS. The easy out is made from special hardened steel, and my cobalt bit are not even making a dent.

I ordered some diamond bits for a dremel, but those things are hardly working at all.

Can anyone tell me the best practice for using these diamond bits? They seem to be making about 1mm per hour progress, and I'm going through bits pretty fast.

[JEEPRUSTY]

Another Easy out horror story.
remove the head and take it to a machine shop.

[LoopGaroo]

Yea, I really don't want to do that until i'm legitimately out of options.

[cowboyup3371]

Jeep is right, this is an all too common problem and all too common warning that users should stay away from them (SEARCH THE ARCHIVES).

[JEEPRUSTY]

Yea, I really don't want to do that until i'm legitimately out of options.

Well It sucks but you are only looking at hours of frustration and will likely cause more damage than you have already.

[LoopGaroo]

Well It sucks but you are only looking at hours of frustration and will likely cause more damage than you have already.

Along the same lines, I worry that I'll cause more damage pulling the head, and drifting further into unfamiliar territory as I try to put everything back together again

[LoopGaroo]

Hi.

Not sure it would work but you can remove the bolt around the easy out. Then wiggle it out.

DP

That's a good idea, I've been going right down the middle.

[Billy Ricks]

If you can get to it you may be able to chip it out a little at a time. They are brittle as hell. I had one break off in an exhaust bolt once and once use them again. I chipped it out and then drilled and tapped what was left of the bolt.

[Testarossa]

Kevin, I work in a machine shop so I have the luxury of having the proper tools to make these type of repairs. I have been successful at removing broken easyouts by using solid carbide endmills. The carbide is harder than the steel used to make the extractor and will cut it, but you can't try and horse it out. If you can find an appropriate sized endmill (say 1/8" diameter 4 flute solid carbide,) then you could try to use that in your dremel. It will have a tendency to grab and get away from you in a real hurry at dremel tool speeds. It would be a lot easier if you had the head out and were using then endmill on a Bridgeport. It will be very easy to cause collateral damage with the endmill if you are unable to control the dremel tool by hand.

[tom203]

Hi.

Easy out aren't.

I once read tread about a guy getting a diamond tipped bit.

Yeah, but it has to be held real steady- like in drill press- or you know what happens!
You (loopgaroo) could try drilling around ezout with small drills - even into threads in head- and helicoil later. Next time use a left handed drill bit - safer than ez outs for this problem, cuz once they bite into and weaken the stubborn bolt, it sometimes just spins out.

[LoopGaroo]

Yea, I actually had two sheared bolts when i started. I botched this one with the Easy-Out, then took a break, did some research, and bought some left hand bits and took the other out - no prob.

Now I'm back to square one. I've started to ask around the ChiVinMoto group to see where I should take the head if i choose to go that route.

[LoopGaroo]

I guess there's a shop nearby that charges $25 for Electronically disintegrating the bolt. That is awesome. I'm kinda sad because that's half the price of the left hand bit set i bought... not to mention the p.o.s. easy-out

[LoopGaroo]

I have no idea, and couldn't find much on Google. I'm just happy it's affordable.

[Steve]

It's called "Electrical Discharge Machining" or EDM. (<--click link)

.

[Testarossa]

EDM is the absolute preferred method for removing broken bolts, taps, drill bits, easyouts etc. Won't damage the head like drilling can. Basically a high electrical current will be applied to the offending bits and they will simply burn out.