broken bolt HELP

[ChevyCowboy]

so im in the middle of rebuilding my 1990 honda Fourtax 300 and my brother snaped a bolt off in the camsaft cover luckly i can get it off and work on the wrkbench with it. we tried every way we could to get ahold of the broken end an we tried turning it with a chiesel nothing worked so then we drilled it out and tried an extractor that broke also so know im stuck with a hardend steel bolt extartor stuck in a bolt in an aluminum cover any one have any more ideas how i can get this damn bolt out anyhelp would really be appriciated

[grancito]

Bit late now, but bolts gets corrosion around them in aluminium, and the way to free them is with heat. Oxy-acetylene is needed to get the heat to the bolt fast. You could try putting a nut over the broken stud, and put a 1/16" electrode inside and weld the two together, the heat will weaken the corrosion.

[ChevyCowboy]

hey grant
i had thought of doing that with heat but if i get enough heat on the bolt to breake up the corrosion wont i run a risk of warping the aluminum?

[hraney]

hey grant
i had thought of doing that with heat but if i get enough heat on the bolt to breake up the corrosion wont i run a risk of warping the aluminum?

probably not with a torch. It is real hard to pour enough heat in a chunk of Aluminum that big. The bolt will break free a long time before the head warps.

[grancito]

I agree with that, have heated many bolts in ally castings without a problem.

[625fireman]

I agree heat is the way to go. One thing I have had luck with when they break off close to the housing is to weld a falt washer on first then the nut. Small mig welders work pretty good for that if you access to one.

[962500]

you could always drill it out tap it and put a helicoil into bring it back down to the original size.

[grancito]

I don't have a MIG welder any longer, but find that welding inside a nut onto the stud using a 3/32 electrode works well.