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[Arctic John]

Ok...I admit I messed this one up royally!!!  My son has a Sportster, noticed that one of the exhaust flange bolts was broken at the block.  Good 'ole Dad says, "No problem, I remember how to do that".  (first mistake)  So I drill it out to an acceptable size to take the easy-out, insert, twist, and break the F-ing easy-out!!!  Holy Moly, I don't remember this part.....

So I have a broken bolt with a broken easy-out, of course I can't grab any part of it. 

Called the dealer and they say "Bring it in, we will remove the head and send it to the local machine shop, then reinstall the head".  About $600 repair !!!!

Any ideas, cause I know I can't be the first to ever do this......or do I learn a $600 lesson?

[dartman]

Your not the first and wont be the last, unless the bolt is inaccessible any good welding shop should be able to weld a nut to the broken stud from inside the opening and back it out.

[2harleys]

Bite the bullet and let the professionals do it. If you are already into the block, and a "hardened" easy out is broken off inside of the stud, you have a problem. There are several ways to remove that easy out, but it is sounding like you do not have the proper equiptment in your garage. If you were drilling into the block with hand tools "on the bike", it is a strong possibility that the drill  was not perfectly straight anyway. Remove the head, and let someone with the proper tools and knowledge fix it before it is non repairable.

[Dwight]

I spent most of my life as an industrial machinist and have removed thousands of broken bolts using the "weld on a nut" practice.  Only a few times have I needed to do more than just chase the threads in the hole.  Like mentioned above, find a good weld shop.

Dwight

[Arctic John]

Got it....$600 lesson and let a pro do his job. 

I'll try welding a nut on it and then quit. 

I guess it could be worse....it could have been MY bike !!

Thanks....

[cahdbiker]

Arctic John, I am not familiar with your engine, but if the stud does not protrude into the combustion chamber of the  cylinder head I would try the following. If you can get at it try a drill bit with a carbide tip on the easy out. If you can get even a small hole started in the easy out, then switch your drill to reverse. Sometimes those easyouts seem like they are totally stuck and with a little GENTLE patience they will come out and then you could continue your drilling. If you can get straight on it just keep increasing your drill size  until you can use a larger easy out. When I have been in similar situations I have just kept increasing my drill size until the walls of the stud are very thin, then use a larger easyout and have gotten good results. (If you decide to try to keep drilling put some liquid wrench on it and let it sit overnight) Also sometimes heating the area around the stud will help. This is my 2.5 cents I hope you can fix it without giving someone all that money over a simple mistake. GOODLUCK CAHDBIKER

[bigjohn]

Arctic John, I am not familiar with your engine, but if the stud does not protrude into the combustion chamber of the  cylinder head I would try the following. If you can get at it try a drill bit with a carbide tip on the easy out. If you can get even a small hole started in the easy out, then switch your drill to reverse. Sometimes those easyouts seem like they are totally stuck and with a little GENTLE patience they will come out and then you could continue your drilling. If you can get straight on it just keep increasing your drill size  until you can use a larger easy out. When I have been in similar situations I have just kept increasing my drill size until the walls of the stud are very thin, then use a larger easyout and have gotten good results. (If you decide to try to keep drilling put some liquid wrench on it and let it sit overnight) Also sometimes heating the area around the stud will help. This is my 2.5 cents I hope you can fix it without giving someone all that money over a simple mistake. GOODLUCK CAHDBIKER

                        X2

[Twolanerider]

Only one small suggestion to add to the ideas above.  Doesn't help now but might for future reference.

I hate easy outs.  Probably just like everyone else.  If you need them you're already in trouble.  And if they break you can be in bigger trouble. 

Once in awhile they can be avoided though.  Whenever drilling out a broken bolt I used left handed twist bits.  It's the only time I ever use them.  But a good percentage of the time you can see the bolt you're drilling start walking (or at least moving) when the bit has drilled through a bit and relieved the hole.  That the bit is twisting the direction you want the bolt to walk can't hurt.  Have had the broken bolts walk out completely with the left hand bits quite a few times.

[Arctic John]

Interesting concept twolane...,.If only I could do this over again...

Of course, I never really want to do it again, but next time I have something broken that needs fixing, I think I will START with a requesrt for assistance and THEN try what I know is the right thing....sure would have done this one different......