broken bolt question

[GSXRBOBBY]

I was installing the valve covers on my Northstar and had a bolt brake off, just the tip so I could remove it, it neede to be drilled out. I started to drill it out and then the tip of the drill bit broke off. Any ideas on what to do now?
P.S. the heads are aluminum so heat may not be good.

[dguy]

Carefully build up what's left of the bolt & bit with a MIG welder, until there's enough there that you can grab on to with a pair of pliers, then twist out.

Some people prefer to build it up until they can weld a nut on to the stub & use a wrench or socket instead of pliers.

The heat from the welding should help to free up the bolt.

[aaron88]

If your lucky you can weld to it like don said.  Good luck.

If that doesn't work you are stuck redrilling the hole larger until you can get in there to weld.  It really is the only option I can think of for your delema.  If the bolt was broken off flush or sticking out a bit there would be some more options, but I think you are stuck with only one.


Aaron

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[GSXRBOBBY]

I will have to try it tomorrow.

[GSXRBOBBY]

I got the bolt out!!!!! YAAA...
I had just enough of the back of the bolt sticking out the rear, thank goodness it was a corner bolt. Enough to rest the ground up againist. I then used the MIG welder and welded a few spot welds on top of each other, tapped the side of the head with a hammer and used a small pair of Vise grips. I built up the weld just large enough to fit the Vise grips. I had to do it three times though, the first started to turn and the weld broke off, the 2nd didn't really even connect much and the third worked. Thanks alot for the help guys, I don't even need to rethread the hole, the threads are fine other then were I hit it with the drill bit on the first 2 or 3 threads, but no big deal, it has about 12 to 15 more to hold on to. Just need to run a chaser down it and I should be good to go.

[aaron88]

Good to hear.