I usually tap lightly on the center punch, then look very carefully to see if centered. If so, then center punch again with a harder hit. That way, you can adjust your punch mark if not centered. Then, as said, start with small bit, like 1/16, and work your way up. Take time and patience. Its not an easy thing, so don't get mad. Try to hold drill as straight as possible. If muscles begin to fatigue, take a break, then go back at it. Hopefully its not a grade 8 bolt--very hard. Even if you wind up off center a bit, you can drill until you get close to the threads, then use center punch to knock it loose, or try to turn it out with center punch an hammer. Drill as large as you can, before you get into the threads, possibly use an easy out. I've drilled large as I could, accidentally off center, then knocked the remainder of the bolt around and sort of chip it out, then back it out in direction of threads.
And yes, if you have access to a welder, weld a bolt or anything to it, then work it back an forth as you turn it out.
Douse it with penetrant as well.
Just work with it as you go, and if off center, play with it till you get it out. Takes alot of practice. I've only hit dead center a few times, and was very proud when I did. Of course, clean the female threads up with a tap when done--oil it alot, and go slow and easy. You don't want to break your tap off. If you do, they are brittle due to hardness, and you can chip it out with a center punch as well. If you wind up getting into the threads, not the end of the world, just go to auto shop or wherever and get a heli-coil kit for that size thread, and install. Directions with heli-coil kit. Inserts are also available, if to wallered out to install a heli-coil.
Patience, take breaks, and do your best. Tis a difficult task, no easy way.
Again, if you are unsure and it is a critical bolt, take it to a machine shop--let them enjoy the headache.
Probably more good advice comin' from others...good luck.
Dan
On Edit--easy does it when drilling, breaking a bit off only complicates things...
This post was edited by dbernie at 20:24:08 03/24/11.
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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
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