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Old 05-19-2023, 11:16 PM   #2
ford38v8
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Location: SF Bay Area
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Default Re: Off topic--drilling out broken bolts/studs tip

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Another method is to use a gasket as a template on a thick aluminum plate, and drill a pilot hole in the precise center of the hole on the plate. Bolt up the plate, and while using the pilot drill bit in a hand drill, graduate up in size until the broken bolt is thin enough to unscrew itself. I used this method with an exhaust bolt without removing the engine.
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