If you know someone, or know someone who knows someone who has a welding
machine, they might do it for little or nothing.Ask around.
cuhulin
The cost will be so variable because of many different things including
how creative the person is, how accessible it is, if they've ever done
something like that before and how much risk they feel is involved.
Remember, you are saying "drill it out and tap it" which may not be
possible because they would need to drill at least to the ouside
diameter of the thread plus the next tap drill size and THEN tap it to
some larger size. This would mean that there would have to be
sufficient room in the case to do this. If you would use some kind of
thread insert, the hole may have to even be larger. Without seeing the
exact problem, I wouldn't be able to give you an estimate...

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CraigFL
http://www.automotiveforums.com
hls - 06 Sep 2007 21:32 GMT
> The cost will be so variable because of many different things including
> how creative the person is, how accessible it is, if they've ever done
> something like that before and how much risk they feel is involved.
Exactly. We have discussed this sort of problem on this group several
times in past years. There are ways to handle almost any kind of broken
bolt issue, but as it becomes more complicated, the cost goes up.
Having a broken EZ Out in the hole doesnt make it any easier. IIFC,
there are companies which can remove the bolt by electrochemical
machining methods and do little damage to the threads (and like everything
else, there are always exceptions).
He needs to put that sucker in his car or truck, amble down to the best
machine
shop in town, and chat up the folks there.