Creative way to remove this snapped off bolt?

Joined
Oct 8, 2011
Messages
3,671
Location
Madiganistan/Chiraq
Top of a battery terminal.
Trying to help a neighbor.
Anyway to get this out?
I don't have a welder.
1000033047.webp
 
Can’t weld it IMO. It’s on a battery and the sparks will explode the battery.

I’d drill a hole in the bolt and try an easy out.

Just my $0.02
 
4 options-

1. drill it out
2. drill and tap another hole next to it
3. use the lower hole by adapting the current cable end to match
4. use dremel and cut a slit on the broken bolt and use a flathead screwdriver to remove
 
EZ Outs always break.

LH drill bit, but there's a danger of drilling into the battery so I'd mark the depth on each bit and step up in diameter once or twice.
 
If the extractor broke off in the hole, you are done there. Too hard to drill. You may have to chisel or close quarters hack saw the thing off the post, with out cracking the case. I would be afraid of a Dremel saw due to sparks.

P.S. I think I would use a close quarters hacksaw.
 
How deep of a hole do you have with the extractor down there?

You may have enough clearance to drill to the next size tap size and cut threads with a bottoming tap. Cut a few good threads and grind the lead threads off the tap to get a few more turns before bottoming onto the broken extractor.

Perhaps a new battery is easier. It comes with less Tylenol.

Crazy me, I would try to get a key locking thread insert in that hole. 🤪

Wait....that's a ~$125 battery (Amazon). Buy more Tylenol and go at it!
 
How deep of a hole do you have with the extractor down there?

You may have enough clearance to drill to the next size tap size and cut threads with a bottoming tap. Cut a few good threads and grind the lead threads off the tap to get a few more turns before bottoming onto the broken extractor.

Perhaps a new battery is easier. It comes with less Tylenol.

Crazy me, I would try to get a key locking thread insert in that hole. 🤪

Wait....that's a ~$125 battery (Amazon). Buy more Tylenol and go at it!
I drilled it out as far as the bolt went in on the other side. Mb 3/8in or a bit more.
I drilled until I just saw a tiny bit of soft lead at the bottom of the whole.
I think the metal of the bolt was just pressing *out* straight into the softer metal and that's why it couldn't ould come out.

The good terminal looks like it has like a steel insert into the soft lead. Like a time sert.
Different than the terminals that have a loose nut underneath.

The battery is actually testing really well. Date code 4/20. i don't think it is junk yet.

Yes crazy how expensive it is. An nearly as much as a car battery that is 3x larger.
 
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