Broken bolt

[dig dug mx6]

I finally located a 4 to 1 for my bike and in the process of removing the old pipe I busted a header bolt off. I have tried just about everything to remove it. I even busted off a bolt remover in the bolt too. FO now I have a way to rig a fix with a U-bolt on the frame pushing the header on instead of pulling it tight.

Any ideas on how to fix. The only thought I have is to try and drillit all out and rethread the hole. THe problem is the bolt reover that is busted off in there is really damn hard.

[smallegange]

What I have done the last time this happened to me:
I drilled little (1.5mm) holes around the snapped boldremover and then took it out. Then drill exactly in the midlle of the bold and rework the thread. And use a lot of Neversees or coppergrease the next time!

[dig dug mx6]

Trust me now the ones that came out ok are cooated in neversieze. I am thinking these bolt have been the bike since it was made almost 20years ago.

[chuckycheese]

Same same

I had a similar problem once when I broke off an extractor. It freaked me out because those "easy outs' are really hard steel. If I were you, I'd talk to someone at a machine shop. Those guys are used to dealing with horrid problems like that and will give you great advice....and may be able to solve your problem with little difficulty. Good luck!