406oc.co.uk

Hi everyone

Had a bolt that snapped off when i was putting new roll bar bushes on. Its the drivers side and its the bolt thats nearest to the front of the car. The bolt thats left has about 4mm of thread protruding from the hole. So far i've heated it up with a blowtorch and used a freeze spray and it still won't budge. Drilled whats left of the M10 bolt with a 6mm drill bit (started off with 1mm and worked up 1mm at a time) drill bit snapped but i drilled straight through the bolt. Tried an easyout even though i was a bit sceptical from previous experience and that was no use. Now i'm thinking i'll just have to drill it out with a cobalt drill bit as the hss drill bit didn't seem upto the job

I did contemplate just welding a nut on whats left of the bolt but as its right next to the fuel tank(drained it off already) i don't think that's an option.

When i first started unscrewing the bolt i managed to unscrew about 5mm of the bolt before it snapped. The bolts were soaked with plus gas for about a week.

has anyone had this happen and whats the best way to get the darned thing out? I'm thinking it must be rusted solid.
Any ideas would be appreciated. The mobile mechanic i usually use doesn't seem to want to touch this job so i guess i'll have to diy.

Thanks
Marco

You're mostly there now, so I'd just finish off drilling it out and tap the hole again.

I'll have a go at drilling the rest out on monday not much time this week working a lot of split shifts . Need a decent set of cobalt drill bits they should cut through the bolt like butter. Then i guess i'll have to use the tap if the thread is knackered might have to go up a size to M12.

I can't believe what a nightmare this job has turned into! Thanks for the advice.

Hi everyone

just an update on the snapped bolt. The bolt came out today, The mechanic snapped 2 cobalt drillsand it took 3 hours to do it so god knows how long it would have took me. I'm pleased with the end result and it only cost £70.