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[Mogulbumm]

Ok, so I purchased a set of floorboard extenders from harleygoodies.com and they showed up just a few days later. Looked to be a really quick mod, just removing the two original bolts, adding spacers, and using the longer chrome bolts supplied with the kit.

Right side went on in under 10 minutes, the majority was working the odd angle to get the inside bolt. Left side was a dog to get off. Had to break out my 2' torque socket to get the leverage. Was in the process of installing the new kit and, with just a fraction of an inch to go, had to torque the new bolt and snapped it off.

So I spent the better part of two hours drilling with a carbide bit and a touch of motor oil to keep it cool.  Finally made it through the bolt, widened the hoe with another bit, and started using a reverse threaded bolt extractor. A couple of turns with that and SNAP, broke that bit off in the hole of the original bolt. WTF???  So another hour of the carbide bit and made NO progress through the new piece. Just gave up for now.

Any ideas as to how to get that out?  The original bolt is really cranked in there and now I need to deal with an even stronger broken removal bit in the hole. Im also worried about breaking a new boot next attempt.

Simple bolt-on upgrade my ass.

[danner55]

You need to get that broken EZ out, out. You are not going to be able to drill it out. Try using a small chisel , vice grips, turning right to get it out. It won't be easy.Go to Auto Zone & get some Blaster It will help Loosen up that bolt.  As far as the original bolt hole. If  you can't get it out,  get a heli coil repair kit. I believe it is 3/8 bolt.  You will have to drill it out bigger to accept the heli coil. It can be done, just take your time.  

I just installed the floor board extenders on my CVO last week. I had to washer my right side about 1/4 inch or I would have had the same problem as you did. The left side went on with no problem.

I hope I was able to help you out. Good luck!

[Cvostu]

That sucks!   Good luck.  Hope you can get it.

[cvobiker]

sounds like the bolt suppled was too long (or something lodged inside the bolt chamber) and end butted when you were torquing down. At the point you are at, i would take the part into a machine shop and pay them $50 bucks,, unless you know someone.

Good luck  

[cahdbiker]

Mogulbumm, I just read your post. Hopefully you have fixed your problem by now. If I understand correctly you broke off a bolt, drillled out the center, put in an bolt extractor and the bolt extractor broke off so now you need to drill a hole in the center of the bolt extractor, get it out so you can get the bolt out of the hole. If you can even get a small hole in the bolt extractor pound a round punch in the center of it and turn it clockwise Ideally a manuel  impact wrench on the end of the punch  set to turn in a clockwise direction usually will remove the bolt extractor. Sometimes those bolt extractors feel like they are locked in place, but if you can get them to move slightly in a clockwise direction they will come out of the hole. If you can manage to get to this point then I would continue to increase my drill bit size until practically nothing is left of the original bolt except the threads and by then it will be easy to remove.( I try not to use bolt extractors because they are so brittle ) I have used this process many times because when I was younger I was a chronic bolt breaker. I hope it works for you. Please let us know when and how you fixed your problem. Just thinking about it makes me want to take a xanex and drink a beer. Good Luck! CAHDBIKER

[Mogulbumm]

sounds like the bolt suppled was too long (or something lodged inside the bolt chamber) and end butted when you were torquing down. At the point you are at, i would take the part into a machine shop and pay them $50 bucks,, unless you know someone.

Good luck  

Just something wrong with the hole I think. The replacement bolt is exactly the length of the original plus the extension piece. It would be well worth $50 but I need to drive my bike 30 mins to get my exhaust done and it's a bit tricky with no floorboard. Threads are in the frame.

[Mogulbumm]

Great advice all!  I wish I could drill from the inside but there is just no room. I'll keep at it with the cobalt bit but that freaking bolt extractor is hardened steel and I wasn't getting far. Took today off with the kids and will hammer at it a bit more tonight.  If I can get the extractor out, I'll keep sizing up the hole in the bolt since I was making slow but steady progress there.

I really appreciate all the tips!

[Cvostu]

I know how frustrating that must be.  I know, I break bolts of now and then still.   I did one just a few weeks ago while tightening my shifter lever that connects to the trans.  That was a three hr job. Inner primary had to come off along with the rest that also had to be put back on.   And a new lever with a brand new bolt.  Have patience and don't let it get the better of you.   You'll get it.  When you do, please let us know we are all rooting for you.   

[Chains]

You do not have anything in your tool box that will let you drill the easyout, it has too high of a rockwell to drill, typically if one breaks a tap or bolt extractor/easyout there is a process to burn them out, not good when in the frame..  If you cannot turn the easyout to the right, do you live close to a muffler shop or a small auto repair?  They can mig or tig a piece to the easy out and you can put it with the extra leverage.  Once it is out if there is enough of the bolt sticking out the same thing can be done with it.  It is a tricky deal, but a good welder can get you out of trouble.  If you get the easy out to break loose, go with the cobalt drill but do not exceed the tap drill size.  Then you can buy the appropriate tap and run it in, be carfull though backing the tap out every few turns to not let it load up with chips or you will end up in the same problem when you break the tap.

Good Luck

[cvobiker]

Mogul

Any luck with your bolt problem 

[dartman]

If I recall correctly my Floor Board Extenders came with a caution to run a tap in the bolt holes to eliminate such a problem developing, I did not do it on all of them but I had two that started to turn with difficulty and removed them and chased the threads with a tap. Any good welder can put a nut onto your broken off easy out and back it out, i have had broken head bolts removed and it took about 10 minutes,

[Mogulbumm]

Ok, so I haven't had time to drill away at it... more to come tonight.

In the interim

1. Where can I purchase a TAP

2.  What size would I need for the floorboard bolts? Anybody have the specs on them?

[dartman]

Your directions should mention bolt sizes,  If your local store has them in stock, for occasional use these are fine http://www.harborfreight.com/hand-tools/tap-die/40-piece-sae-carbon-steel-tap-and-die-set-39391.html

[cahdbiker]

This is good advice. Anytime a bolt is chromed the threads are chromed which makes it a little bit larger. I never thought about that in my first response to your post but whenever you see people building a bike on TV show they are always running taps thru the frame before they install the new chrome add ons. Let us know when you get it fixed. CAHDBIKER

If I recall correctly my Floor Board Extenders came with a caution to run a tap in the bolt holes to eliminate such a problem developing, I did not do it on all of them but I had two that started to turn with difficulty and removed them and chased the threads with a tap. Any good welder can put a nut onto your broken off easy out and back it out, i have had broken head bolts removed and it took about 10 minutes,

[CBW]

a small Carbide burr in a die grinder. Very slow and tedious process,but works very well on getting through broken taps and easy outs.