How to remove a broken bolt with no head
 

My Air Pump mounting bolt broke when I was removing it, so if anyone know a way to remove the broken stud, or any ideas id really appreciate it

Do you have piece to grab sticking out or is it in a hole?

If there is nothing to grab onto then you could get a bolt extractor. Heat it up, Liquid wrench it, then use the extractor. Quick google search yeilds..

http://homerepair.about.com/od/inter..._extractor.htm

u can pick a set of deadbolt removers from Home Depot it's not going to be easy though so make sure you know what you are doing before hand.

If there is a piece extruding out you can do a couple things.

-Use vice grips but you have to be very careful the tool doesn't slip at all, or it will just make it worse.
-Tighten two nuts down over the existing thread, and 'loosen' the bottom one until it is pressing against the top, and keep putting torque on it, and it will spin the stud eventually.
-Weld (or try JB weld) a nut onto the end of the stud, and go from there.

If you heat up the area with a torch before you begin any of those, it will help, and you can let it cool down too.

If its not sticking out, you're most likely going to have to take it to a machine shop or use bolt extractors, although using the extractors rarely results in success in my experience.

Usually they brake inside and you really f...d because you can't drill them out.

If you salvage airpump anyway - you can probably just cut it off somehow.

Yeah once there are three extractors broken off inside the remnants of the original stud, you can officially start crying. :wallbash: :lol:

anyone ever heard of a countersink bit?

Hey Ernesto - did you get that bolt out ?

Later

Hey guys, I was at work all day long, but just wanted to get some ideas. Yes unfortunatley, the broken bolt IS stuck inside of the hole and there is NO part sticking out to grab onto. The thing is, I have NO money to buy another air pump until next friday then another 2 weeks till it arrived (altogether 3 -4 weeks??) I dont think so. I know its hard work but if anyone knows how I can get the bolt out when theres nothing to grab on to ( something to drill inside etc) plz let me know, I'll have all day sunday and monday to do this

First you will need a center punch to make and indentation in the center of the broken bolt. You will then have to get an extractor set which includes a drill bit and different size extractors. When drilling, you need to keep the bit lubricated and try your best not to drill fast and, try to stay at or around the same rpms. If you go too fast you will just burn up the drill bit.
If you are in need of another air pump, I have one available and..it's polished. $45, shipped.

soak the bolt with penetrating fluid for a few days... get a reverse drill bit and a reversible drill... center punch the bolt ( the more accurate the better) pick a drill bit that is slightly smaller then the shank of the bolt

slowly drill it out, spraying penetrating oil every so often... it is important that you keep the drill straight while your drilling... more then likely the bit will grab the bolt and unscrew it.

Sorry I don't have $45, most I can give pay for an air pump right now is $ 30 shipped. DHL is about half the price as USPS and UPS, and I think the air pump wieghs about 20lbs? My brother used DHL for all of the things he sold and he said he never had a problem with them. The cost for shipping I estimated to be about $10, so you would get $20 profit maby a little more. If your interested just check DHL for a price quote, and then let me know,but otherwise, I think all I can do is wait for more $ :tear: lol

Actually I just came up with another theory. Instead of removing the broken stud, I could swap clutch/pulley assemblies with the damaged Air Pump I have, and put the "better quality parts", on the damaged air pump to repair it. That way I don't have to remove any broken stud, as the damaged air pump does not have a broken stud in it. This is highly experimental and im not sure if its been done before, and I may break something along the way, but it is FREE, and things would get done right, so it's worth a shot, i'll try this on Sunday.

Do as Chinaman described to get that ole broken bolt out Ernesto.

Later you can do a writeup on how to extract a broken bolt ! Go Ernesto !



Later

can you push it out? meaning if the other end open? if so drill a small hole then screw another screw into it and use that to screw it out. if not just drill the whole thing out, use a thread maker to makea new hold and bolt ot fit.

take a cutting disc on a dremel, and make a flathead type slot... use a standard screwdriver and take it out :icon_tup:

Impact screwdriver would probably work better, but good idea.

always able to improve an idea, thanks! but seriously:icon_tup:
take a dremel, cut a slot-

if not you can just drill it out and helicoil it or rethread it a different size.

use a f-ing removal tool or drill it through from the back if u can get to it

Thanks for the input. I wil start on this job tommorow, and I will keep you posted

Clever.

Not sure what you talking about, but if it's bolt I think of (top one) - it broke inside. There is no way to use dremel.

It's PITA. I broke mine close to end, like 1/8 sticking from airpump ear inside. So, I had to split airpump open on a car and use pray bar to get it out.

Ya so I got pretty anxious to see if my plan was going to work or not, so I actually fixed everything tonight, but I didn't have to remove the broken stud to fix it, read below...

So the reason why I ordered another Air Pump was because my stud was broken inside of threads with no way to grab onto it. When I receieved my Air Pump from somebody on this forum, it was damaged. Click here for more info: https://www.rx7club.com/showthread.p...84#post8547984

I removed the bad parts off of the damaged Air pump and threw them away, and replaced them with the parts of the better quality air pump I had. The damaged air pump doesn't have a broken stud in it so, problem solved. Im not sure if this has ever been done before, maby it alrerady has, but anyway here's some pics.
Taking apart the damaged Air Pump
Attachment 706107

Removed the pulley
Attachment 706108

My Air Pump ( Right) and damaged Air Pump (Left)
Attachment 706109

My pulley (Right) damaged pulley (Left)
Attachment 706110

Stripped back wire insulation
Attachment 706111

Twisted wire together tightly, and wrapped in heat shrink
Attachment 706112

Installed black wire insulator
Attachment 706113

Installed repaired wiring unto Air Pump
Attachment 706114

Installed/swapped pulley
Attachment 706115


Finished Product
Attachment 706116

im not 100% sure if this will work or not, but the connections are all tight, and I have continutity on both wires, so I don't see why not.

Except 1 little thing.. It sqeaks! Iv'e read about lithium spray type grease that will never dry out, does anybody know of any lubricants that will stay lubed without drying out?

i really hope you dont break a bolt off into the engine anywhere. That would get expensive. I couldnt imagine replacing my whole engine for a little bolt.

It probably would of been easier for you to spend 6 bucks on a extractor with the matching drill bit. drill a hole in the bolt. Than place the extractor in it and turn in reverse.

Would of taken about 5 minutes of your time.