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Old 07-24-2009, 05:31 PM   #1
1FSTREX
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Join Date: Mar 2006
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Location: Biergarten in Deutschland
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05 STI
CGM

Default Need Help: Broke a bolt off in the chassis and its stuck!

***UPDATE***
- The bolt is stuck in the chassis of the vehicle in the forward sway bar mount hole next to the fuel inlet pipe.
- There was a drill bit stuck inside of it

So i decided i would cut the bolt around the drill bit with a hack saw. This worked and the exposed portion of the bolt fell off leaving a portion of the drill bit exposed. I used a pair of vice grips and twisted the drill bit out. I tried again to use some extractor bits but unfortunately the hole is offset to one side of the bolt and not centered so the extractor bit wouldnt work. I was going to try and drill a new hole inthe center but unfortunately i couldnt get to the center of the bolt, because the other hole already covered the center. I decided finally to just try and drill out the bolt, only to find out that the hole already drilled was extremely slanted and i ended up drilling into the side of the mount hole. So now the hole is f***ed. No there is no happy ending to this story.

Basically now all that i can think of to fix it is to take it to a shop and have them take off the inlet pipe, drain the tank, drop the tank, remove all the charcoal crap, and then do one of two things.
1-drill out the rest of the bolt, get a helicoil and drill a hole for that to fit into and do it that way.
2-drill out the rest of the bolt and then get the threaded portion of a bolt that will fit through the hole on the cobb sway bar mount and then weld that threaded bolt to the chassis so instead of the bolt going through the cobb sway bar mount and screwing into the chassis. the sway bar mount actually slides over the bolt on the chassis and then gets locked on with a nut. Make sense?

Any other ideas out there?
Shop suggestions?
Etc?

F...M...L!!!!


Hey guys,

So im an idiot and i broke the head of a bolt off and the bolt is stuck. The bolt is located on the rear of the car, its one of the sway bar mount bolts and happens to be the one right next to the fuel inlet pipe. I believe the bolt is cross threaded and is extremely jammed. It gets worse, i tried to use a bolt extractor and accidentally broke off the drill bit inside the hole i was drilling. I have tried vice grips, pliers, and drilling the drill bit out and nothing is working. So i am basically in all kinds of ****.

So here are my questions:
- any ideas on how i can get the bolt out?
- any ideas where i can take it to get it removed?
- can i drive my car to the shop without the RSB on it?

Thanks guys,

Will
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Last edited by 1FSTREX; 07-25-2009 at 12:33 AM.
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Old 07-24-2009, 05:51 PM   #2
steeter
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Default

So here are my questions:
- any ideas on how i can get the bolt out?

I would use heat, then depending on how much of the bolt is visable....pic?

I might take an air chisel and square off the bolt to get a better grip with a wrench, pliers etc...again a pic would be nice.

- any ideas where i can take it to get it removed?

Any shop that you trust.

- can i drive my car to the shop without the RSB on it?

Sure, just take it easy.
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Old 07-24-2009, 06:02 PM   #3
1FSTREX
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Quote:
Originally Posted by steeter View Post
So here are my questions:
- any ideas on how i can get the bolt out?

I would use heat, then depending on how much of the bolt is visable....pic?

I might take an air chisel and square off the bolt to get a better grip with a wrench, pliers etc...again a pic would be nice.

- any ideas where i can take it to get it removed?

Any shop that you trust.

- can i drive my car to the shop without the RSB on it?

Sure, just take it easy.

Thank you great response, my only concern with the heat is that the bolt is right next to the fuel tank and the fuel inlet pipe.

I am at work so i can get a picture when i am home. The problem with flatening it out is that there is a hole in it now where the hole was drilled for the extractor, so if i shave it i will have a knotch taken out of it.

Will
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Old 07-24-2009, 09:37 PM   #4
Horkus
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Get yourself a carbide bit on an angle grinder, grind off that drill bit, then when you see the normal bolt material, continue on using a new drill bit and be careful this time until you get the whole bolt out, use a tap clean out the threads and hope you didn't mess up the thread too much.
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Old 07-25-2009, 12:34 AM   #5
1FSTREX
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Quote:
Originally Posted by Horkus View Post
Get yourself a carbide bit on an angle grinder, grind off that drill bit, then when you see the normal bolt material, continue on using a new drill bit and be careful this time until you get the whole bolt out, use a tap clean out the threads and hope you didn't mess up the thread too much.
Pretty much what i tried to do, didnt work i just made more of a mess of things. update
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Old 07-25-2009, 12:48 AM   #6
EROC263
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I agree a pic would be nice but if you could drill it out to where it would just be a hole in the frame, you could use a rivet nut. It's basically a threaded insert that pinches itself in the hole.
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Old 07-25-2009, 12:11 PM   #7
1FSTREX
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Quote:
Originally Posted by EROC263 View Post
I agree a pic would be nice but if you could drill it out to where it would just be a hole in the frame, you could use a rivet nut. It's basically a threaded insert that pinches itself in the hole.

Thats what i am thinking i will do, only problem is the hole is right next to the fuel tank inlet so i am not sure if i can do it properly without removing it. I think its time to just get it fixed professionally.
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Old 07-25-2009, 02:17 PM   #8
Horkus
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I think this is a real challenge for the pros
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