The Ford Barn

Mart · 12-14-2013, 12:56 PM

I've been buttoning up an engine, basically put together from parts I had around me. Virtually the last thing to go on was the clutch pressure plate. 6 of the correct bolts were rounded up and the clutch and plate fitted. Just putting that final little tweak to make sure they are tight and the last one snapped.

Dayum!

I didn't want to take the sump pan off again, as it had already been off and on again twice(!).

I tried to drill the bolt with a drill I had resharpened to cut as a left hander but it didn't work very well and started to go a bit off centre.

I regrouped and decided to improvise a bush.

I got a short length of 5/16" brake tube and a short length of 1/4" tube. I had to drill the larger tube to fit the 1/4" tube inside.

They were pushed into the hole.

And a 3/16" drill was used to drill into the bolt. The bush was good enough to get the drilling back on centre.

I don't have any easy-outs, so I used a T30 torx bit and hammered it into the remnants of the bolt.

The bolt remnant came out successfully on the first attempt.

Here's the bolt with the retrieved end. You can see the splines broached into the end by the torx bit.

I think there is a time and place for easy-outs or my improvised version. Removing something that is rusted in place so tight that the bolt shears while trying to remove it is NOT the right application. A bolt that snaps due to material defect or overtightening IS the right place for them, as the remnant isn't tight in the hole.

Mart.

12-14-2013, 12:56 PM	#1
Mart Senior Member Join Date: May 2010 Location: Solihull, England. Posts: 8,755	Another setback averted! Broken bolt removed ! I've been buttoning up an engine, basically put together from parts I had around me. Virtually the last thing to go on was the clutch pressure plate. 6 of the correct bolts were rounded up and the clutch and plate fitted. Just putting that final little tweak to make sure they are tight and the last one snapped. Dayum! I didn't want to take the sump pan off again, as it had already been off and on again twice(!). I tried to drill the bolt with a drill I had resharpened to cut as a left hander but it didn't work very well and started to go a bit off centre. I regrouped and decided to improvise a bush. I got a short length of 5/16" brake tube and a short length of 1/4" tube. I had to drill the larger tube to fit the 1/4" tube inside. They were pushed into the hole. And a 3/16" drill was used to drill into the bolt. The bush was good enough to get the drilling back on centre. I don't have any easy-outs, so I used a T30 torx bit and hammered it into the remnants of the bolt. The bolt remnant came out successfully on the first attempt. Here's the bolt with the retrieved end. You can see the splines broached into the end by the torx bit. I think there is a time and place for easy-outs or my improvised version. Removing something that is rusted in place so tight that the bolt shears while trying to remove it is NOT the right application. A bolt that snaps due to material defect or overtightening IS the right place for them, as the remnant isn't tight in the hole. Mart.