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Old 09-04-2010, 10:38 PM   #1
johnathon.sprague
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Default need help getting an easy-out out!

Camshaft cap bolt broke off when I was torquing to 2002 wrx shop manual specs of 20N-m. I think its a typo because 2004 shop manual says 10N-m. Anyway, I used my smallest easy-out on it and it broke off. Should of used the next size up. I've gone through about 8 drill bits including sharpening several times and can't drill through the hardened steel of the easy-out. I'm agrivated and stopped my engine build for the night. Any advice would be great.
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Old 09-04-2010, 10:46 PM   #2
2gnt2wrx
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Can you take a pic?
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Old 09-04-2010, 11:11 PM   #3
johnathon.sprague
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coming up in just a min.
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Old 09-04-2010, 11:40 PM   #4
johnathon.sprague
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Here are some pics of my mistake and my rallispec hybrid build.


http://i937.photobucket.com/albums/ad213/standrd250ridr/IMAG0017.jpghttp://i937.photobucket.com/albums/ad213/standrd250ridr/IMAG0016.jpghttp://i937.photobucket.com/albums/ad213/standrd250ridr/IMAG0014.jpghttp://i937.photobucket.com/albums/ad213/standrd250ridr/IMAG0019.jpg
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Old 09-04-2010, 11:44 PM   #5
theonlygreat
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Broken cam cap bolts before myself, usually they are just finger tight once the head breaks off. I have removed them with just a small flat head screw driver and just a little slot punched in them.
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Old 09-04-2010, 11:48 PM   #6
johnathon.sprague
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I might try something like that but I think I tightened it considerably by wedging the easy-out in it.
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Old 09-05-2010, 12:59 AM   #7
PSolbergfan
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Try finding a norseman's drill around that size. It's a reverse drill bit. It cuts while rotating left versus a standard drill that cuts rotating right. This will help extract the bolt. The FSM manual is wrong on that spec. The front cap is 10 N.m. and the two rear caps is 20 N.m.
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Old 09-05-2010, 01:43 AM   #8
FuJi K
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That is one mistake many often do.

The OUTER most cam cap, or say the one right behind the cam gears are 7ft lbs. The Cam CAPs inside the valve covers are 14ft lbs.

If you looked at the bolts, you may have picked it out. But it's ok, you didn't do a WHOLE buch in damage at all.
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Old 09-05-2010, 03:03 AM   #9
johnathon.sprague
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Yes, the 2004 specs with 10 n.m. make more since, but the ken-gilbert website with the 2002 wrx shop manual says 20N.M. so I thought since I had 2.0 heads those were the specs to use. I realized when I was torquing that it seemed like a little too much for the bolts about the time one of them broke. I guess I will buy some left handed drill bits, or carbide bits and see if I can slowly drill through the EZ-out. I'm thinking I will end up mauling out the threads. I will have to figure out something though because these are DPR stage IV ported and deshrouded heads.
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Old 09-05-2010, 11:19 AM   #10
col5555
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spark erosion if all else fails
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Old 09-05-2010, 02:55 PM   #11
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1 carbide #30 pilot (in drill press)
2 stair step upper portion of hole with a#21 bit (carbide)
|#21|
| |
\ /
| |<#30
3 easy-out the easy-out + PB blaster
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Old 09-05-2010, 03:32 PM   #12
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Quote:
Originally Posted by col5555 View Post
spark erosion if all else fails
EDM FTW.
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Old 09-05-2010, 03:39 PM   #13
johnathon.sprague
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I bought a bunch of carbide drill bits today and still cant drill through the broken off EZ-out. I'm a little frustrated.
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Old 09-05-2010, 03:40 PM   #14
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Its going to suck if I have to hual my motor to a machine shop for EDM.
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Old 09-05-2010, 03:46 PM   #15
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Quote:
Originally Posted by DSM_Outback View Post
EDM FTW.
Not the same, you can't EDM a Blind Hole.
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Old 09-05-2010, 03:59 PM   #16
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Im thinking about tapping the top unthreaded portion of the hole and using a helicoil and washers on the bolt. Anyone think this is a bad idea? I only need to get 7ft-lbs of torque on it.
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Old 09-06-2010, 07:04 AM   #17
col5555
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Quote:
Originally Posted by MartinSTi05 View Post
Not the same, you can't EDM a Blind Hole.
I know nothing about the ins and outs of spark erosion but I am sure I saw on a cylinder head sight they use it for this very purpose. The EDM in this application uses a flushing cylce.
Please correct me if I am wrong just trying to help out.
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Old 09-06-2010, 10:38 AM   #18
MartinSTi05
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Quote:
Originally Posted by col5555 View Post
I know nothing about the ins and outs of spark erosion but I am sure I saw on a cylinder head sight they use it for this very purpose. The EDM in this application uses a flushing cylce.
Please correct me if I am wrong just trying to help out.
Spark erosion differs a bit. EDM uses a wire that is immersed in fluid and is secured from both sides. Spark erosion could work as it is not required that a wire pass through the part.
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Old 09-06-2010, 11:41 AM   #19
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Quote:
Originally Posted by johnathon.sprague View Post
Im thinking about tapping the top unthreaded portion of the hole and using a helicoil and washers on the bolt. Anyone think this is a bad idea? I only need to get 7ft-lbs of torque on it.
I'd drill the whole threaded portion out and helicoil it. Helicoils are pretty long. At least longer than you'd need for that size bolt. Still, the amount of thread engagement that the OEM bolt has shouold be retained. Use a stock bolt with no washers.
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Old 09-06-2010, 09:04 PM   #20
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Pampers are diapers and Kleenex are tissue and tomatoes are tomatoes...
Split some hairs here....MDM FTW: Metal disintegration machining.
MDM/Spark Erosion like that which is used to remove broken taps etc would be a form of EDM.
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Old 09-06-2010, 09:46 PM   #21
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^^ + 1
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Old 09-07-2010, 12:05 AM   #22
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I did the EXACT same thing...I took it off and brought it to a machine shop. I also had to buy a new HG.
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Old 09-07-2010, 12:08 AM   #23
johnathon.sprague
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I am going to call a machine shop about EDM in the next day or so. I am half tempted to drill from the backside of the hole and try to drill out the bolt.
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Old 09-07-2010, 12:29 AM   #24
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you should try a left hand bit.
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Old 09-10-2010, 12:48 PM   #25
charliew
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Is the ezout flush with the surface? If it is you can weld a nut to it through the center of the nut and use the nut to turn it out. This works on cast iron really well. I've never tried it on aluminum. The heat will expand the aluminum and the bolt will expand less and get loose. Try to get a handle on the torque specs of the different diameter bolts it will dave a lot of agrivation in the future.
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