Broken bolts - a pain

[Bren]

I have been fitting rear pads and braided hose to my GSXR750. Due to the position of the caliper it was easier to remove it fit the new pads. No problem.

 

Until one of the bolts holding it to the carrier snapped.

 

As the had had broken near to the top I could not get the caliper over the remains of the bolts. I had to centre punch it then (very carefully) start drilling until it's length had been reduced enough to get the caliper off.

 

I then tried the favourite of a nut welded onto the stud in the hope of getting it loose - not a chance, the nut kept snapping off until it was flush with the carrier. Arses.

 

Get the centre puch , keep drilling using progressively larger bits. I then had to retap the hole with a M8 tap which worked. Both holes are still in exactly the same place. As for the bolt, could'nt get one locally so had to order one from Robinsons foundry.

 

I spent around 4 hours on one broken stud - even with the right tools they truly are a PITA.

[skattrd]

Yep, I spent a day once drilling and re-tapping the threads out of a turbo flange.

It's tedious, annoying work, which you just don't expect to take anywhere near as long as it can do.

[MikeKnight]

Usually happens to me right at the end of the job, or at the last section of work on said job, making my cheerful mood of "oh nice, I can go home in an hour" to "get someone to bring me takeaway food because I'm here all god damn night",

[Station]

Got two exhaust bolts snapped in my Saab engine head which means either take the head off or lift the engine which means days of messing round again.

[Des]

Is that an old 900 Saab with the comedy random long studs and spacers? I've managed those in situ by starting with a big drill bit that fills the hole in the manifold snugly, used that to get a centred start on the stud, then carried on drilling with a small bit, right through, squirted penetrating oil up the hole, had a cuppa, then hammered a torx bit up the bastard.

[Station]

It's on the newer b204 engine, not the cantered type. Kindve worried about it, but will leave til last I think.

[jonny69]

Sometimes it's easier to just bypass it all, drill it oversize and fit a helicoil. I keep meaning to buy some left handed drills for occasions like these, too.

[fordperv]

Agree with the helicoil comment, both hub pinchbolts on my saph were seized and snapped, as I couldn't be arsed waste the whole day sorting it I cheated and sent it to an engineering company I use for heads, block boring etc they did them for me at a vet reasonable price and as a bonus my day was free to complete other tasks

[robinmasters]

I find it tends to happen just before you finish taking something apart, just as you're thinking 'Only took an hour to get it apart, that's the hard part-I'll be done in time for dinner and The Professionals.'.

[Des]

memfast.co.uk do some interesting inserts.

[Lacquer Peel]

Have you got a blow torch? I find it works wonders with rusty bolts and nuts.

[Station]

You need propane or oxyacetylene ideally. Holding a blowtorch over a rusty bolt for half an hour only to snap/round the head off always seems to be the case with me

[Lacquer Peel]

I have a cheap 'Go System' butane/propane blow torch and it's fugging ace, not sheared any bolts recently with that thing on the go.

[rainagain]

I have a cheap 'Go System' butane/propane blow torch and it's fugging ace, not sheared any bolts recently with that thing on the go.

Having spend eight hours today messing with seized bolts I'm going have to give this a look!