need help with rusted broken and/or rounded bolts

[juntjoo]

I have a bunch of rusted bolts that have broken that I need to remove and have been attempting to use one of those inverted drill bits that as you can see broke:

You must be logged in to view this image or video.

and one of those bits you use to finish screwing into the broken bolt counter clockwise to extract it which you can see below I've also broke, which now the top is stuck in a broken bolt

You must be logged in to view this image or video.

and tonight, with the rest of that bit, which would have been enough for this bolt that connects the caliper halves, I tried to extract this bolt but now the part of this little hand wrench thing, sorry I don't the names of most of these parts and tools yet, is now too rounded to even properly grip this extracting bit.

You must be logged in to view this image or video.

so now in three different holes I've got two parts to this extracting bit stuck and one has the end of a broken inverted drill bit, all of which are made of materials harder than bolts I've been trying to extract, so am I now going to need an even tougher application to remove this crap mess I've made or what? what am I doing wrong here that I've ended up with this worse situation. thanks for any help you guys can provide. as you can see I definitely need it.

 

[Bud92gsx]

The easy out works pretty well. But drilling and tapping is also a very good idea.

 

[97Chitclipse]

Heat is your friend when it comes to stuck and broken bolt

 

[Bud92gsx]

I also have 6 sided and 12 pointed sockets for more rounded bolts..And if that fails, I have this thing called a gator grip socket..That usually gets the more rounded ones off.

And if that fails.Chop the head off, and drill and tap, or the easy out.

 

[juntjoo]

The easy out works pretty well. But drilling and tapping is also a very good idea.

okay, just checked that product. looks like a heavier duty set of similar inverted extracting screws with the same square make ends. I'd rather connect a socket to it or something more trusting than these weakly gripping handles. is there another way to grip them? you see, you'd think that they were made to grip the bit right enough by tightening them into the bit by hand, but it still list grip and rounded itself. am I using the tool wrong or was mine cheap you think?

 

[bryanwheat]

That easy out is way to small for a bolt of that size. They are a hardened material so you won't be able to drill it out. You will have to shatter it with a punch or chisel. The best bet for a very rusty bolt like that is to drill it out like 95 percent of the way to the edge of the threads than run a tap thru it.

 

[92AWDHX40]

I always use some pb blast and soak it for a while or so then a little heat and slowly remove my bolts been doing that for years some break anyway then i have to drill them out and then do a tap.

 

[juntjoo]

what is that thing called? a tapping handle or something? is that my only option with any kind of screw extractor? should it get rounded like that or is mine defective/returnable?

 

[92AWDHX40]

I drill mine out carefully then make a tap depends on where the location is, or improvise sometimes you gotta do that.

 

[Bud92gsx]

Tap and die. It tapps the drilled part and puts a thread on it. Very helpful.

 

[YanDsm]

The best way I always remove my broken bolt is MIG welder. I weld on the bolt slowly and taking care of not weld all together and I grip my weld tack with vise-grip. The heat generate by the weld is almost always enough to loose the bolt.

 

[juntjoo]

alright I get it, heat. perhaps this rust bucket of mine requires heat for all of its rusted bolts. but what do I do now with this?

You must be logged in to view this image or video.

I know I turn it clockwise and it will come out but since I got it in I want to get that bolt out. that handle is done. I say its cheap, tho I don't know, but do I really buy another or do I get a bigger one or is there something else maybe better at gripping this extractor bit so I can get this bolt in there out? already tried gripping it will a variety of vice grips

 

[juntjoo]

I can't even grip it enough to remove just the bit turning clockwise

 

[bryanwheat]

Use vice grips to tighten the handle down on the easy out.

 

[juntjoo]

Use vice grips to tighten the handle down on the easy out.

already tried. handle is crap. inside the part that grips bit is rounded. I'll figure it out tomorrow. thanks anyway

 

[bryanwheat]

Just use a crescent wrench on the easy out them. That easy out is going to break on that brake bracket bolt though.

 

[juntjoo]

okay, "easy out" is that inverted screw that is stuck. and no, nothing is gripping it, least likely a crescent wrench. think of how stuck it is, and how little the end of the easy out and on top of that its made rounded. reading up on how to use these tools properly in these situations are very tricky... and will rape you in your arse if you don't get it right. I think i'm buying a fat torch tomorrow. I have a little pen sized torch. not good enough

 

[bryanwheat]

okay, "easy out" is that inverted screw that is stuck. and no, nothing is gripping it, least likely a crescent wrench. think of how stuck it is, and how little the end of the easy out and on top of that its made rounded. reading up on how to use these tools properly in these situations are very tricky... and will rape you in your arse if you don't get it right. I think i'm buying a fat torch tomorrow. I have a little pen sized torch. not good enough

Anything without oxygen isn't going to get it anywhere close to hot enough to do anything.

 

[juntjoo]

again I don't know what you're talking about probably because of my noob level, for which I apologize and again thank you for your help. anyway, found this on "Jerry's broken drill and tap removal service": "Any steps taken from this point can become very desperate. You might try the ez-out anyway and break it, NOW what? Anger and frustration could set in, large hammers, chisels and maybe even torches come out and all rational thinking is gone. At this point the probability of success is remote and the possibility of destroying the head or manifold is very high. Besides the aggravation and the cost to replace or repair damaged parts there could result in weeks of wasted time from improperly using the ezy out extractor tool." so i'm not the first monkey who's screwed themselves incorrectly attempting to remove broken bolts. it sucks to end my Sunday after hours of work with nothing accomplished. well, I could tell myself in order to accomplish what I set out to do takes some education... time and some money, a good amount of which I went through this very trying Sunday. s$#!, now I gotta drive my civic. I think I should clean my apt for the rest of this day

 

[juntjoo]

You must be logged in to view this image or video.

my first attempt with fire.

 

[bryanwheat]

Those extractors aren't going to work with a bolt that is actually seized like that. They are for bolts that were just snapped from over tightening. You will break those all day long. you either need to drill the bolt out and retap the hole or weld a washer to the remaining stud than weld a nut to it (this is hit and miss with a bolt that seized). The heat from welding it will loosen up the rust. Also a little propane or mapp gas torch isn't going to do anything but make the metal hot. You need a cutting torch if you want to make any progress with heat. I would recommend just buying another caliper bracket.

 

[juntjoo]

You must be logged in to view this image or video.

you telling me this bad boy isn't enough? never welded more than soldering some electronics. what else do I need? i'm getting this out. too late to quit

 

[bryanwheat]

You must be logged in to view this image or video.

you telling me this bad boy isn't enough? never welded more than soldering some electronics. what else do I need? i'm getting this out. too late to quit

Yes i am telling you that extractor isn't strong enough to get that out. The bolt is seized well enough that it snapped the 12mm shaft, you are just going to keep snapping those extractors off. They aren't meant to get seized bolts like this out.

 

[mattasi]

You must be logged in to view this image or video.

you telling me this bad boy isn't enough? never welded more than soldering some electronics. what else do I need? i'm getting this out. too late to quit

X2 on wanting to know.

 

[bryanwheat]

X2 on wanting to know.

Because it doesn't get hot enough to really do much. As i said before, if you don't have an oxygen mix you are not going to get the metal hot enough.