Extracting a bolt from aluminum

Bones · Jul 31, 2008

We have a problem here Houston

Installing brackets on the new bike for the hard bags.

go to install said bracket on the left side

Per instructions use 2-8mmx30mm allen bolts, if your VIN ends in 235345 use this 5mm spacer, mine did not so no spacer is needed, run the bolts in...well damn! the spacer is needed. Go to back the bolts out and they do not budge, snapped both off about 3/8" left hanging out of the subframe. Not a chance vice grips will get it out.

I am afraid that if I cut them off flush and try drilling them out to attempt an EZ out (doubtful), or just one size larger and retapping the holes and using a size larger bolts than before. Easier said than done getting everything center punched dead nuts. Last option and my personal favorite is finding a guy that can TIG this bracket to the bolts with the spacers and all that.

Am I on crack to think this is a proper fix? I can get pics if needed of my F-up

Bones · Jul 31, 2008

Or get that putty from BILLY MAYS!

P · Jul 31, 2008

I vote Billy Mays, that guy has two thumbs and loves to eat ***** !

laughing1

Bones · Jul 31, 2008

P said:
I vote Billy Mays, that guy has two thumbs and loves to eat ***** !

laughing1

vagaina staind beard. Love that idiot

blacksheep10 · Jul 31, 2008

do you have a small torch, like the ones taht are wine bottle size and create a little heat? you weld a nut on the broken off bolt, that gives quite a bit of heat, then you quench just the bolt so it shrinks and is freed, then put a little heat around the area, keep quenching teh bolt with pb blaster, then turn it on out.

Bones · Jul 31, 2008

blacksheep10 said:
do you have a small torch, like the ones taht are wine bottle size and create a little heat? you weld a nut on the broken off bolt, that gives quite a bit of heat, then you quench just the bolt so it shrinks and is freed, then put a little heat around the area, keep quenching teh bolt with pb blaster, then turn it on out.

#1 problem no welder or this would not be a problem as teh bracket would be weldered on by now. molaugh

Bolts came with paste red loc-tite on them from the factory as well.

Thing that bugs me is once it was in there it would not BUDGE coming out. I literally watched the shank of the bolt fail and the bolt never turned at all. So the other side that went on fine likely will never come back out, so why not just weld the damn thing on there....once again, am I on crack. Pics to follow tonight

Bones · Jul 31, 2008

Taking it to a welder Saturday morning to get the bracket TIG'ed on there unless I get some wild hair up my ass tonight to hack it all up and make it even worse.

blacksheep10 · Jul 31, 2008

well, maybe welder guy can't get the bolt out first then weld the bracket on.

Bones · Jul 31, 2008

blacksheep10 said:
well, maybe welder guy can't get the bolt out first then weld the bracket on.

Not going to take the bolt out. Plan is to put said spacers on the bolt, weld bracket to said spacers/bolt from the back side, then fill in the hole where the bolt head was. I'll get pics tonight, maybe there is a more logical...less permanent way to go about this screw up. The bike is new dammit, 600 miles.

6uldv8 · Jul 31, 2008

It's ****ed! Get out of it while you can!

Bones · Jul 31, 2008

6uldv8 said:
It's ****ed! Get out of it while you can!

trading it this weekend for a Harley

6uldv8 · Jul 31, 2008

Bones · Jul 31, 2008

You got a better idea slim?

Matt would tell me I could have a rig by now... :flipoff1:

bigsilly · Jul 31, 2008

Bones said:
Or get that putty from BILLY MAYS!

you are talking about

Bones · Jul 31, 2008

yer got damn right son! :woody:

6uldv8 · Jul 31, 2008

Kelly is talking about the standard method but from what I've seen of bolts seizing coming out of aluminum.....it's gonna be a friggin mess. If the tig idea you've got will work then it's probably gonna be the neater/cleaner route. Pics will be interesting though!

Bones · Jul 31, 2008

Pics in a couple hours.

Some are saying heat will loosen that loc tite and if I can double nut it, should be good. My vice grips are POS harbor freight

6uldv8 · Jul 31, 2008

I missed the part about the "loc-tite".....if that's what's holding them then you may be OK..but "loc-tite" holding enough to break the bolt off seems extreme.

Bones · Jul 31, 2008

No way to get it double nutted

Applied some heat and my crappy vice grips and nothing. Thinking of just welding the hookers and being done with it.

blacksheep10 · Jul 31, 2008

damn, that's an EASY fix with a welder. weld a nut to that bolt and quench after 15 seconds with PB. it'll back right out. oh well, you tigging what to what? ???