Seized - Snapped bolt

[kiwikodi]

Hi all

So when removing the lower crank case bolts, one snapped off below the surface. I managed to get an easy out to grip and started extraction. Sadly, the easy out also snapped. I got the casings back today from aqua blasting and he wasn’t able to extract it either. Can I get some advice, hints or tips on how to fix this?? Or if someone knows anyone North Yorkshire, North East based who could help. Please.

[zed1015]

The obvious method it to get is spark eroded but if you are steady handed the easy out can be chipped out or ground with a small carbide burr and a dremel etc.

[Al]

I had three 8mm at the front snap in mine. Took them out with a dremmel. Took all day but didnt do any damage. Can recommend.

I do this a lot at work as i get this stuff every week. Use a plain steel washer over the hole and with a (preferably) three phase MIG fire a single puddle onto the top of the snapped bolt. Before it cools down place a 10mm or 12mm plain steel nut over the washer and do the same but fill the nut to flush. Hopefully you can use a socket (not spanner) to wind it out whilst its still hot. Try it whilst its still at full heat but be prepared to wait 'till it cools a little and sometimes till touch warm. If the nut snaps off it will normally take the washer with it. Try again.
AL

[kiwikodi]

Thanks both. Dremel it is. Stupid question but what brand of burr can you recommend. Got a set of tungstens to cut some alloy recently and burned through like 8 in an hour. An Amazon type link would be great?!

[Al]

I used mounted stones a bit like these. You will burn through many so 10 may not be enough but cheap so could buy 20. These are 4mm so in theory you could drill to 4.00mm and take it from there.
AL
https://www.ebay.co.uk/itm/10PCS-MOUNTE ... 2977232712

[kiwikodi]

Quick update. All done. The stones were shite. The ends kept coming off in the shaft but a combination of stone and carbide tips and a bit of patience and it’s all re tapped and ready to clean and paint. Now anyone want to give suggestions on the painting process? Is it worth tackling it myself or best left to the pros - also how on earth do I cap off all the non painting ends?