so i'm working with a buddy on fixing up his 24v swapped car. He was doing the thermostat and decided to hulk out on the housing bolts and broke one off. BTw I called him a dumbass and lol'd pretty hard when he did that so that took care of that. Now he needs to extract the broken part. Any tips on doing this?
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extracting bolts
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Centre punch it VERY carefully, I like automatic centre punches myself. Then drill using incrementally larger drill bits until you are at the proper size for the E-Z out. If the E-Z out works, awesome! If not keep drilling incrementally larger until you have drilled out the bolt, if you are careful you can drill the bolt out without damaging the threads in the housing. Be careful with the E-Z out, they are very brittle. You will need an unobtanium drill bit to drill out the E-Z out if you break it. If you aren't careful and drill out the threads in the housing by accident you will have to install a threaded insert such as a heli-coil.
Make sure you are as accurate as possible throughout the whole process, from centre punching to each step of drilling. You can walk the drill bit a little bit as you go up in sizes to stay perfectly centred on the bolt but be careful not to flex the bit too much or it will snap.
'89 Alpine S52 with goodies
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