The Stovebolt Site Forums The Shop Area General Truck Talk Broken bolt removal (tailgate hinge)

I am still trying to remove a broken off bolt. It is the upper bolt of the tailgate hinge. I have tried an ez out with no success...and have tried to drill out with no success. The drill bit that I have used is a regular bit picked up at the hardware store. What am I doing wrong? I can't believe the bolt in there is hardened or anything like that....why is this not working?

I am thing about drilling the spot welds out of the stake pocket and replacing the whole thing but would rather not do that. Can anyone suggest the proper drill bit to drill this bad boy bolt out? :confused:

What is happening when you run the drill bit thru the bolt. Did you center punch the broken bolt to make sure youre drilling only the bolt and not part of the truck too. I think those are 5/16 bolts. how abt. if you drill just the bolt slightly smaller than the threads and run a 5/16 tap thru the hole?
Good Luck,
Marty

Blue 50,

You say you have tried to drill it out with no success. Does this mean the remaining bolt seems too hard for the drill to penetrate, or that it runs off center and you can't get it started in the middle of the bolt! Bolts can work harden as they wiggle and break. You can also turn a drill so fast on the broken screw that it will work harden.

If you have a torch you can anneal the broken portion by heating it red hot and letting it cool by itself. This is hard to do without a oxy-acetylene setup using a very small tip.

If you can access the other side of this screw, you have another chance at it using a small sharp drill bit started in a center punched hole. Use some type of cutting oil and keep the drill speed down. A easy out cannot be used unless you get a hole at least partially through the broken bolt, and then it must not impinge on the threaded portion of the hole itself. Are you sure you are holding your mouth right when you do this!

Stuart

You might be using the wrong type of drill bit, too. You need a split point drill bit, preferrable either a high speed steel or better yet, a cobalt bit. You'll want bits that are rated for use in metal.

Not being a smart a@@ but I have seen this done more that once, especially with you getting flustrated, is the drill turning the right direction???go with aa small a bit as you can and work your way out.

Not being a smarta&& either,,but it seems on these kinda things the wind has to be blowing just right,,your right foot has to be pointing south/easterly,,and the newspaper has to be open to page 34.
In other words,,,leave it be for a couple days and come back to it with a fresh frame of mind.

heat it and cool it 3 or 4 times to and keep oiling it tap on it with a hammer the more you move that metal around the looser things will get abuse the poor thing

Guys,
Thanks again for the info...to give a little background:
naw, I didn't center punch the bolt fist (first mistake)

drill speed was too high (second mistake)

wrong drill bit (third mistake)

foot pointed northwest (fourth mistake)

I was wearing the correct tin-foil hat though, LOL....it's a wonder I make it through the day without adult supervision!!

Try heat first and if that doesn't work ask for one of these at a local industrial supplier. Good luck.

Curt B.


http://cgi.ebay.com/10-Pcs-1-4-Soli...218QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

That worked out the best for me too 32Fire2. If not heat it again but this time get a BIGGER hammer.

tech tip may help.
I've used this trick on my old indians

http://www.stovebolt.com/techtips/brokenbolt.htm