I was taking off all the front dress v-belt set up on my engine to get it ready for the serpentine swap and there is a bolt that had been previously broken off near one of the water ports.

I was able to use a small drill bit at first then a larger drill bit without problem. Then I finally got to use my handy-dandy easy out .... snap!
Now what!!!???

I have tried using tiny drill bit’s around the side of the easy out breaking three of them. I have tried using a couple of small Dremel grinders and I’ve made a tiny bit of headway, and I have tried using small chisels to hammer and break it up, all to no avail.

Any help would be appreciated.

Maybe keep stepping drill bits up until you get closer to a thin wall of bolt left. Then you can use a larger rescue out or chip away at the thin wall left.

After that, I’d re-Tap the threads and then use anti seize on those bolts when you re-install.

Or- drill a bigger hole so you can use a larger rescue. If possible, also hit it with some heat right before you try to back it out.


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The hardened easy out is what is broken off, stuck inside the bored out bolt.

Get a 1/4 carbide center cutting 4 flute endmill and put it in an air die grinder. It will be 20-30bucks but it will cut right though the easy out and everything else then you can drill it/retap it. Hard part is staying centered but it can be done with patience. Did this on Willy's exhaust manifold bolt and worked great

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Thanks for the advice Mike and David...
I saw the Carbide...then passed because of what you said exactly...$20ea.

Ok, I'll try that this afternoon! Still better to pay $20 than to have to load it all up and take it to a shop!

A set of reverse drill bits?

Heat first tho.

If you have anything hardened, like a drill bit, broken off in the hole don’t follow up with a like hardened tool. You’ll just break that as well, at this point it’s time to invest in some more expensive items, carbide and die grinder.

Carbide will cut it.

Take your time. Rushing will make it worse. Take breaks if needed.

Seems to be a theme here!!! CARBIDE it is!
Gracias!

If you are able to stay centered and slowly size the hole up near the threads you will be able to pick the remains of the bolt out and chase it with a tap.

So everything I read prior to asking you guys said to chip it apart because its SOOOOO BRITTLE!!!
BS...
Well all I seemed to do is pack it in there as deep as possible and now I’m stuck with the arduous task of trying to grind it out!!!

I’m making progress, slooooooowwwwwly.

For next time - before you try an easy-out, I have had great luck with reverse drill bits. Usually I don't get too far in before the bolt just backs out on it's own.

Let us know how you come out!

17 days laaaaaaaterrrrr... multiple, Multiple attempts.

Success