Oh boy, broken bolt on water pump cover...

[Twitchs_Tackle]

Finally found the time to tear into my water pump issue on my 8hp Merc kicker. Things were going surprisingly well (should have been an indicator) disassembly was quick, clean, then BANG... the first bolt I tried to remove from the water pump cover (4 bolts) 'popped' under slight pressure. Hadn't even really begun to turn the ratchet and thought "oh, that came loose easy" then half the bolt came up out of the hole :passout:

The other 3 came out like nothing was wrong:cool: So I worked my way down to the stump of the broken bolt (sticking up about 1/8") from lower unit block. First, tried the vise grip approach... nada. Then tried heat from small butane torch. Nope. A couple sharp pops with a hammer to jolt loose the bind... bolt is laughing at me now. Finally resorted to EZ out, which ended as I expected, too small of a bolt to tap, just peeled the 1/8 stub off the top of the lower unit.

Now, I have a very stuck, flush-broken bolt that I need out for reassembly. What are my options. Drill and re-tap?


Aargh! :passout:

[Highmark]

You are going have to remove the bolt that is strill there. If not you will never be able to drill and tap the hole. If you can file off whats left of the bolt till its flat on the top serface of the lower unit. Now you can use a center punch and center punch to bolt head and drill out the bolt almost
all the way thru till it would start drilling in to the housing and stop there,I would Start with 16th
Cobolt or tungstun drill as a starter drill to create a pilot hole for the next drill to follow.
Hopefully with out damaging the housing. We do this often down at
work on Aluminum housings. So it can be done.Go buy a good ez out set
off the Snap on truck.They have the type that you drive in to hole and the stub is 1.500 long and
a sleeve that drops over the stud you just inserted in to the hole.
that sleeve looks like a nut to turn to bolt out. I have used this type
of extractors many times. they are the best. Good luck.

HM

[twisted lines]

That starts out with your ability to drill a straight hole, If you are going to try it start small and check that you are centered each drill bit, if your off you can cheat it the way you need to move, Left hand drill bits can help if they grab it might come out. don't know what you have for ez outs but go to big and that opion is out you must remove a slinky looking thead if you can drill it close enough, and there are Heli coils if things go bad but I hope for you it gets better soon. Bummer.. and good luck

[baltz526]

you might try to cut a slot with a dremel tool, then use a slot bit in an impact hammer

[budnate]

when stuck like that, I drill a small hole at 12 o'clock right on the edge of the threads, what I mean try to get it in the vise so gravity will help you, be clicking them with the bit when drilling, just big enough for the wd 40 nozzell...use wd-40 and heat it a bunch of times around the bolt to exspand the alum with the small propane torch and shoot it in the hole when its hot, let it cool and do it again it will eventaully work around the threads, I will do this over a few days..be patiant! let it soak and do its thing.

then like the guy said make a little DEEP slot on the bolt and use a good driver, heat it again around the bolt to exspand the alum shoot the juice again, I take a small flat tip punch the size of the bolt and give it a few med taps to shock the bolt and threads also... say a prayer and push the screw driver in tight and use a wrench on the driver and try to rock it L/R if it moves hit it quick again with the juice a little more heat and it should come once it wiggles a little.

I never have any luck with easy outs, they just break in the bolt then your double scre...,

rtv the boo boo area and gasket when it go's back together and use good grease on the bolts and say WOW I earned that one.

peace, B.

[fishkisser]

If all else fails you can send it to these guys ...
http://web.userinstinct.com/2765400-tap-bolt-removal-service.htm

[Lurp]

Drilling a small hole to let wd soak in is a good one
Last time I had this problem I used some modeling clay to build a dam about an eighth inch from the edge of the hole all the around it then fill it up with liquid wrench (I find it works better than wd)
Every time you go to the garage for the next three or four days fill it up again BE PATIENT
then use a left hand drill to drill it for an ez out sometimes the left hand drill will pull it out
If you have to use an ez out be gentle work it left then right not to hard if it breaks off then cut a notch with a dremel tool and use a screw driver with a hex on the shaft so you can put a wrench on it and work it out
If you have to drill it bigger
Instead of a heli-coil use a keen-sert Hall Tool used to carry them lots of hardware stores do
they are an insert threaded inside and out with pins down each side you drive down after you screw it into the hole to lock it in place
They are stronger than heli-coils, don,t take any special taps like heli-coils do, just standard drills and taps
also you end up with the bolt going into steel instead of aluminum so a little never seize on assembly works fine
GOOD LUCK

[Captain Kirk]

If all else fails you can send it to these guys ...
http://web.userinstinct.com/2765400-tap-bolt-removal-service.htm

I think they are using an EDM to do this. There is a guy in Bend that has one and can do it. PM me if you want me to get you contact info.

[fishkisser]

Yep thats the machine ... its amazing to see the results ...

[fillet&release]

I had the sam problem and I ended up welding a slightly smaller bolt to the broken one and was able to turn it out

[Twitchs_Tackle]

Thanks all for the replies.

I haven't had the time (or patience) to tackle it yet...good thing I sidedrift with my electric:wink:

Capt. Kirk, please PM the info to me. I grew up in Madras, still have some friends over that way...

[jmg]

Thanks all for the replies.

I haven't had the time (or patience) to tackle it yet...good thing I sidedrift with my electric:wink:

Capt. Kirk, please PM the info to me. I grew up in Madras, still have some friends over that way...

Let me know when you do tackle it as I haven't seen a good rager in awhile! Good luck with the fix. You up for a carb rebuild job when you're done?

[MattPark]

A sharp, good quality chisel should get it out. I've broken many bolts in my day, the chisel never fails. Just whack it on an edge to dig a good slot, and before you know it, the bolt will start turning.

[Gundog]

The best bet is to weld a nut on the bolt and turn it out. If you can't take an arc welder put the rod on the tip of the bolt turn it on and off real quick use the rod to turn it out. If those methods don't work you will need to drill and tap it. Good luck
Mike

[Chrome Bumper]

Hire a mechanic just for the one bolt. Talent and experience can be priceless. OEM (Oregon Electro Machining) is near you and he might be able to help if you want to EDM it.

[12pulls]

I have used curse words before to try and move the bolt out but usually the bolt doesn't respond. A left handed drill bit works pretty good especially if you have WD-40 it for a while.

[Captain Kirk]

Thanks all for the replies.

I haven't had the time (or patience) to tackle it yet...good thing I sidedrift with my electric:wink:

Capt. Kirk, please PM the info to me. I grew up in Madras, still have some friends over that way...

PM Sent