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Removal of busted off easyout?

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Todd

02-23-2001 18:54:31




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I broke a smaller sized easyout in the transmision housing on a BF minn I have drilled four small holes arond it but if I drill any bigger it will get in to the housing. I have made the effort of drilling direcrly on the easyout but cant get anywhere that way. What next????/




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Todd

02-24-2001 08:17:01




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 Re: removal of busted off easyout? in reply to Todd, 02-23-2001 18:54:31  
Thanks for the input I think I like Steves idea if that fails I WILL Take it to the machine skop.



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Gordon in IN

02-24-2001 17:59:52




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 Re: Re: removal of busted off easyout? in reply to Todd, 02-24-2001 08:17:01  
A Drimmel tool, set on the highest speed, with a diamond abrasive narrow cone shaped "dental burr" and gently snd slowly cut through the "easy-out" (or tap). If you can work the pieces out (and/or using compressed air) you are done. If not, cut the remaining pieces and try to work the pieces out. This works, and if done carefully, will not damage the parent metal part (the threaded hole). It does give a real and new understanding to the terms "patience", "slowly", "carefully" and "gently". The total cost is much less and the time involved is still less than disassemblying the "whole thing" and taking it to a shop to have it "EDM'ed" (which also works). Good luck, ask your friendly dentist for some of his worn out narrow cone shaped diamond abrasive burrs, then grind off about the first 1/4 of the burr which will be worn out. This leaves a burr that is usable for metal cutting of the hardest metals, even carbide. Have fun, Gordon in IN

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Steve U.S. Alloys

02-24-2001 07:40:21




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 Re: removal of busted off easyout? in reply to Todd, 02-23-2001 18:54:31  
The easiest way to get that out is to weld a nut to it. If the housing has been removed where you can position it, I'm sure you can do this. If its an out of position application a bit more experience is required. In that case you could still consider having someone else do it.

If you decide to try it this is the procedure. You need a high alloy stick electrode that has affinity to the tap. The electrode should produce a heavy slag so that the threads will be protected against weld metal deposits. Use the diameter of electrode that will best match the size of the tap and the hole it broke off in. Be certain that you have a good ground. Just put a small deposit resembling a button on the top of that tap and quickly break the arc before the deposit has a chance to over lap the sides of the tap. Keep it just on top. If you need to preheat the tap a bit to get penetration on these short spot welds do that. Repeat the addition of these small deposits until the length of the deposit allows you to set a nut on top of it. Weld the nut to the series of deposits and remove the tap while still warm. You can chip slag between each subsequent deposit but that's not necessary if you can burn thru it each time with the arc. The extra slag actually protects the threads. We sell a rod for this that people use all the time to get out bolts, taps, drills, etc. It's fast and not as difficult as it may sound. Like I said though, in position is much easier than out.

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Al English

02-24-2001 07:25:11




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 Re: removal of busted off easyout? in reply to Todd, 02-23-2001 18:54:31  
Hi Todd, Most of the time one of the do-it-yourself methods will get the job done. But, if the point is reached where the parent metal may be damaged by further attempts, EDM or a milling machine are the best and safest alternatives. Unfortunately they are also the most trouble and cost. Good luck...Al English



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MarkB

02-24-2001 05:53:03




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 Re: removal of busted off easyout? in reply to Todd, 02-23-2001 18:54:31  
This subject came up a few weeks ago. Check out the suggestions below.



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S.AMMER

02-24-2001 05:38:39




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 Re: removal of busted off easyout? in reply to Todd, 02-23-2001 18:54:31  
If you can get to the back side of the easy out you may be able to tap it out with a small pin punch. Heating red with a torch may soften it so you can drill it out (works with broken taps). Have a machine shop or die shop burn it out with an EDM machine. Lots of luck, been there too!!!



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Chris

02-23-2001 19:05:28




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 Re: removal of busted off easyout? in reply to Todd, 02-23-2001 18:54:31  
Know anyone thats REAL Good with a torch? You can blow it out with a cutting torch as the carbon content of the metal is different than the casting and the easyout will go before the block. (Guys correct me if i'm wrong on why this works .)Works with taps and head bolts too. I have done a couple over the years but it makes one nervious as heck.



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