Sometimes it is best to quit while you are ahead and let a machine shop with the proper equipment remove the broken bolt for you.
Having been the poor machinist that has had to fix stuff like this before, it is easier to let the machine shop try to get it out from the beginning than to try and do it yourself, because often you just make it worse.
Last fall my dad and I fixed the exhaust leak on his 1995 F-250 w/ a 460. We pulled the heads from the get-go instead of trying to fight the broken bolts ourselves. The $20 per bolt for a local machine shop to get the broken ones out was well worth it.
If you spent 5 hours on one bolt, letting someone with an milling machine and a carbide endmill tackle it would be well worth it.
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Today's Featured Article - The Nuts and Bolts of Fasteners - Part 2 - by Curtis Von Fange. In our previous article we discussed capscrews, bolts, and nuts along with their relative hardness and thread sizes. In this segment we will finish up on our fasteners and then work with ways to keep them from loosening up in the field. Capscrews, bolts and nuts are not the only means of holding two parts together. When dealing with thinner metals like sheet tin, a long bolt and
... [Read Article]
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