Originally Posted By: maverickfhs
Originally Posted By: Trav
If its in aluminum and broke on removal you probably have zero chance with an extractor unless your very lucky. I use a very small left handed bit and get it dead straight then open the hole a drill size at a time until is almost all gone then pick the threads out with a hardened pick.
Don't drill too deep, use an old bolt to figure out how much is left in there and mark your drill bit. I had to do this on 8 manifold bolts, it came out perfect and I was able to use the original threads, we do it almost daily in the rust belt.
You could also drill it smooth if you buggered the drilling and use a helicoil.
Thanks Trav. I was able to drill a small hole and was able to go through on the other side, then used a left handed bit and now broke left handed bit inside it.
Also, what do you mean by hardened pick?Just regular pick? I'll use your trick and see if I have any luck.
Should I again start the drilling on it now?
I don't have access to a welder
Good picks are hardened steel but some cheap ones will bend and not hardened. Craftsman has some decent ones but don't bother with HF ones or their bits.
So now you have a bit broken off in one and an extractor in the other?
The only bit that will go through both is a solid carbide bit but Jesus don't break that off in there or you will need an electron drill (AKA Elox or tap burner).
It sounds like you got a pretty deep hole dug so its time to stop digging and rethink the situation.