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Once broke

Discussion in 'XJ Technical Chat' started by LaRue, Oct 8, 2008.

  1. LaRue

    LaRue New Member

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    once broke how would you get the manafold bolts out :(
     
    LaRue, Oct 8, 2008
    #1
  2. bill

    bill Active Member

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    Ouch - common wisdom seems to be remove the head and have them drilled out.
     
    bill, Oct 8, 2008
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  3. RickCoMatic

    RickCoMatic Well-Known Member

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    Worst Case Scenario?
    Broken-off flush or slightly deeper?

    The remnant will have to be "Burned" out by a special process machine that will destroy the steel as it arcs to an electrode that is used to create an arc between the steel and the machine. Electrical Discharge Machining.
    An EDM Machine.
    Electrical discharge machines (EDM) work by eroding the material that appears in the electrical discharge path. This material is responsible for generating an arc between the workpiece and wire electrode.
    EDM Capabilities:
    The wire electrode rotates acts as wire EDM tooling and rotates a two-three axis and cuts the internal cavities in the workpiece. There are many types of electrical discharge machines (EDM). Examples include a CNC EDM and a wire EDM machine. A CNC EDM is a computer numerical control machine and is used for removing metal using electrical discharge spark erosion. A wire EDM machine is designed for precision machining purposes and is used for cutting prismatic metal components. Other electrical discharge machines (EDM) are commonly available.

    Oh, yea ... You have to remove the Cylinder Head for any kind of precision work to be done.

    Drill.
    Drill & EasyOut
    Drill & Broken-off Easy-out
    Drill and re-tap.

    The remnant portion of the Stud or Cap Screw is a Soft Steel.
    This means the corrosive oxidation seizing the threaded area is severe.
    Most difficult to overcome.

    The remnant is easily drilled-out.
    Done with precision the Original Threading can be saved by removing enough material from the remnant to re-tap the hole.

    Drill-out and HeliCoil.

    Quick turn-around.
    The remnant is drilled to its working outside diameter and the hole tapped with the appropriate HeliCoil Tap.
    The HeliCoil insert is applied and the piece is restored.
     
    RickCoMatic, Oct 8, 2008
    #3
  4. LaRue

    LaRue New Member

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    Thanks all ooooooooo I was afraid of that
     
    LaRue, Oct 8, 2008
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  5. Pacocase

    Pacocase Member

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    I will second that HeliCoils work great. I had a bolt snap off in the harmonic balancer of my van and I thought I was screwed as I couldn't find another one anywhere. I decided to just drill it out and use a HeliCoil. It worked like a charm. Didn't even mess with the balance!
     
    Pacocase, Oct 8, 2008
    #5
  6. short_circutz

    short_circutz Active Member

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    Drilled mine out and replaced them with 5/16 studs. And brass nuts and washers. Not likely I'll ever have another broken stud while I own the bike.
     
    short_circutz, Feb 22, 2009
    #6

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