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Old 04-21-2005, 10:50 AM
5thElement 5thElement is offline
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I'm trying to remove a broken alternator bolt from the head (the bolt split a bit inside the head surface). In the process, I broke an easy out in the broken bolt (the easy out is flush with the bolt).

I am now attempting to use an acetylene cutting torch per a friend's advice to "burn" the bolt out as he claimed was possible. I have been putting the flame on it with no visible results besides a bunch of soot. Has anyone here attempted this process and if so can you please help walk me through it? I am all out of options here, so any help would be greatly appreciated.
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Old 04-21-2005, 11:25 AM
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anyone got any suggestions?
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Old 04-21-2005, 11:34 AM
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I would not use a torch to get the bolt out, but if you are getting a bunch of soot you have it set wrong, give it more OXY. Though I would not have used an easy out either. Since you have a broken easy out in there now, I would say it will be a miracle to get it out.
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Old 04-21-2005, 11:48 AM
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I work as a welder in a machine shop and we have to remove taps and drills and such all the time. Usually I just take a nut and weld it to the top of the offending article and then back it out slowly. When this wont work due to the tap or whatever shattering, I use a torch to "blow out" the thing. This is a very destructive method so unless you can rebuild the part with a welder I dunno if I'd try it. You heat up ONLY the bolt, NOT the metal around it. When it reaches critical temp. give it a shot of oxygen and keep your fingers crossed that it doesn't do worse damage. If it does, you have to rebuild the hole and then drill and or tap it. You can use a helicoil also. Lemme know how it goes.
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Old 04-21-2005, 02:04 PM
5thElement 5thElement is offline
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I read through some old posts using the search tool, and I found that another temporary option would be to fabricate additional brackets to take the place of the pivot bolt that has broken. I think I might try this route for now if it's a sturdy enough solution. What do yall think I should do?
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Old 04-21-2005, 08:48 PM
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Im 0 fer 2 with EZ outs myself. The last 1 was in a brake caliper bleeder. You can drill out an EZ out. Not fast , but it can be done with a masonry bit that has an edge ground on it. I dont use them them and I tell every one who asks why. Another trick that may work is drilling 1/8 holes in the bolt just out side of the diameter of the EZ out and using a punch to work the piece into it to loosen it. Good luck
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Old 04-21-2005, 09:52 PM
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What about using a left hand drill bit? I have heard of people having luck with them. They drill in the opposite direction and when the catch the back out the offending item. I would assume that you need to go very slow so you don't break the drill bit. I think Harbor Frieght and Grainger sell left hand drill bits. Good luck!
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Old 04-22-2005, 04:39 AM
andy d andy d is offline
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Earl, EZ outs are way too hard to be drilled out with reglar bits.
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Old 04-22-2005, 08:53 AM
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Is the head off the vechile or still on the motor??
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