A2 stainless bolt sheared

ShakeyGS

ShakeyGS

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Servicing my bike today I wanted to measure the valve clearances so went to remove the crash bars.

The front lower M8 bolt was very tight and sheared leaving about 6mm poking out.
I couldn’t really get at it so I had to learn how to remove the whole exhaust system (a positive).

Heat applied with an electric heat gun - no joy
Heat applied with gas torch - no joy
Crap mole grips didn’t help.

Centre punched and drilled the bolt to eventually take an ez-out - no joy

So now I have 5 broken drill bits, 2 wrecked ez-outs and still have around 1mm thickness of bolt left in the hole. My drilling efforts were slightly off - centre too.

So the right side crash bars are now held on by 2 out of 3 bolts

Anyone have any ideas how I can rescue this situation?
 
Of the 6mm sticking out, how deep did you drill into it? Just thinking to restore a flat surface, re-drill 'properly' but get it central this time.

You need to go slowly with ss and cool regularly. Cobalt drills help. Drill with the drill on a low speed.



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May the Lord have mercy upon your soul

Stainless seizing in stainless is a bitch.
There is no easy solution.
On a personal level, I always use copper grease on any stainless bolt because of the propensity for seizing.
Don't think it will ever unscrew. It is seized.
just buy a few good quality drills, and go up 0.2mm at a time.
You may eventually get it out far enough to pull out the "thread" left in the threads, but I doubt it.
Afterwards clean with a good tap set (not Chinese rubbish).
Good luck. You will need it.
Myke
 
Pictures would help with giving advice.

Even if you have drilled it off centre all is not lost. I would drill out the bolt until you cut into the alloy side of the hole. You’ll most likely have a portion of bolt left that looks like a crescent. A couple of options here. Centre punch the widest part of the bolt remains so it falls in to hole created from drilling, or cut it out, as it’s stainless the best option would be a small carbide grinding bit is a dremel if you have one.

Remember that as the alloy will be a lot softer than the stainless steel, any drilling will try and wonder into the softer material.

If you manage to get it out, chances are the hole will messy. However there are a couple of options here, use a helicoil insert, the drill out for the helicoil is bigger than the bolt, and then its tapped out. This should remove the damaged area.

If the hole is too large for a helicoil, then a thread insert can be used, as it’s a larger diameter. But this depends on if there is enough metal around the hole to do this.

Like I said pictures would help to give a solution.


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Cut across the middle with a dremel as deep as you can, then with a flat large headed screwdriver bit, you might get it out, this was how I done it on a pair of Harley exhaust bolt that sheared, you must get as straight in the middle as you can, and if you can get some wd40 around the hole and let it soak a little first.
 
If there is enough bolt shank left and if you have a MIG or TIG welder you could try welding a nut in to it, the heat of welding can help the bolt come free.
 
My efforts have effectively destroyed the bit sticking out so I think I just need to buy some quality drill bits and have another go.

I tried the centrepunch trick but I think there’s too much left.

I’m liking the helicoil idea. Otherwise, I think I did the opposite of everything Karl’s suggests :blast
 
Just an idea but have you tried shrinking it with artic freeze inside the bolt that has now been drilled. Then try again with an ez out bit.
My first option would have been a nut and TIG weld on, the heat from the tig would have certainly eased the sheared bolt.
 
grimo said:
Just an idea but have you tried shrinking it with artic freeze inside the bolt that has now been drilled. Then try again with an ez out bit.
My first option would have been a nut and TIG weld on, the heat from the tig would have certainly eased the sheared bolt.
Click to expand...

+1, too late now battle of the bolt is in full swing, on the plus side if the OP drills too deep the drill bit will have its own supply of engine oil as a lubricant. :eek:
 
You need good drills and a solid force drilling SS.
Could you take it to an engineering shop?
If you hop in the car and drive to Galway, I would get it out for you:D
 
Can I suggest a left hand drill.

This will apply pressure in the "right" direction as you drill.

I have to do the same to my Ducati next week and I'm dreading it....
 
Actually, I think I did ;-)



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