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Car Forum / Driving, Maintenance, Tuning / Maintenance and Repair / September 2007

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Broken Bolt. Machine shop Estimate.

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the_lower_class_brat - 06 Sep 2007 03:37 GMT
Last week I noticed that I had a broken bolt in my GTI transmission
that I bought, I tried extracting it till the extracor broke inside, :
( now I have another spare standard 020 tranny for now, but my
question resides; how much would I need to pay a machine shop to drill
out and tap the hole? Aprox/Estimate. Im fed up with trying myself.
Noozer - 06 Sep 2007 15:58 GMT
> Last week I noticed that I had a broken bolt in my GTI transmission
> that I bought, I tried extracting it till the extracor broke inside, :
> ( now I have another spare standard 020 tranny for now, but my
> question resides; how much would I need to pay a machine shop to drill
> out and tap the hole? Aprox/Estimate. Im fed up with trying myself.

Yes
Steve W. - 06 Sep 2007 23:00 GMT
>> Last week I noticed that I had a broken bolt in my GTI transmission
>> that I bought, I tried extracting it till the extracor broke inside, :
[quoted text clipped - 3 lines]
>
> Yes

If it's a blind hole and you can put it into a position where a liquid
will stay in the hole. You need a few items.

One a heat gun or torch to heat the aluminum part so it is very warm.
A jar of ALUM (Spice sold in a grocery store, usually used to pickle foods)
Clean water.
Some Play Doh or modeling clay.
Small brush.
Needle nose pliers.

Alum has a neat property that we are going to exploit, it doesn't like
steel.

Set up your part so the hole is up where you can see it. Now make a dam
around it so that it will hold more water. Drop some alum into the hole
and use the brush to get it down around the steel as much as possible.
Now add some more alum and some water, you want it to end up a thin
slurry of water and alum. Now use the heat gun or torch to heat the area
around the broken bolt, Don't get it to hot, you want it to get just hot
enough to be uncomfortable to touch. Use the brush to stir the slurry
while you heat the part. Add some more water as it evaporates. Watch for
the slurry to turn black and ugly as you stir it. That is the extractor
and bolt dissolving into the alum. It will dissolve enough of the
threads to loosen the bolt and allow you to remove it in 20 minutes or so.

Then just wash out the hole and clean up the threads with the proper die.

You can also use diluted nitric acid (1/3 water - 2/3 acid) but it gives
off nasty fumes and is dangerous as well.

Signature

Steve W.

* - 06 Sep 2007 16:12 GMT
the_lower_class_brat <the_lower_class_brat@hotmail.com> wrote in article
<1189046228.893557.88440@r34g2000hsd.googlegroups.com>...
> Last week I noticed that I had a broken bolt in my GTI transmission
> that I bought, I tried extracting it till the extracor broke inside, :
> ( now I have another spare standard 020 tranny for now, but my
> question resides; how much would I need to pay a machine shop to drill
> out and tap the hole? Aprox/Estimate. Im fed up with trying myself.

About twice as much as you would have paid had you brought it to a machine
shop PRIOR to screwing up the hole and breaking an extractor off inside the
hole....
Jesse - 06 Sep 2007 18:51 GMT
>the_lower_class_brat <the_lower_class_brat@hotmail.com> wrote in article
><1189046228.893557.88440@r34g2000hsd.googlegroups.com>...
[quoted text clipped - 7 lines]
>shop PRIOR to screwing up the hole and breaking an extractor off inside the
>hole....

I've removed many broken bolts by locating a loose nut over the broken
bold and mig weling inside the onto the bolt shank. Jesse
Thomas Tornblom - 06 Sep 2007 19:09 GMT
>>the_lower_class_brat <the_lower_class_brat@hotmail.com> wrote in article
>><1189046228.893557.88440@r34g2000hsd.googlegroups.com>...
[quoted text clipped - 10 lines]
> I've removed many broken bolts by locating a loose nut over the broken
> bold and mig weling inside the onto the bolt shank. Jesse

Yep, did that to remove some old rusted coolant drain plugs in a 351C
block. Tried the impact wrench first, which only rounded the
head. After welding a nut, applying lots of current/heat they came out
very nicely.
the_lower_class_brat - 06 Sep 2007 19:58 GMT
I'm in the middle of a swap right now and Im fed up with it, so Id
like to just pay someone else to do it. The question was and still
remains, aroudn how much for the job to be done at a machine shop or
maybe evena garage?
cuhulin@webtv.net - 06 Sep 2007 20:16 GMT
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
CraigFL - 06 Sep 2007 20:30 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.
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...

Signature

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.
 
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