Broken bolt any ideas?

[mikecotterill]

Hi ive managed to break the bolt that the chainbrake handle pivots on. What do you guys think to replace it, as the bolt is special I'm thinking I'll have to helecoil it but do helcoils come that small and is there enough available metal? Opinions please cheers mike

[Tyz05]

I think the bolt is the same torx type as the rest of the Stihl fixings, have you still got the sleeve that the brake lever pivots on? You might get the broken stud out if your careful just make sure you drill EXACTLY in the centre. If you have to it could be heli-coiled, there looks to be enough room,be careful drilling the stud to start as you can get into all sorts of trouble else. Start small.

[mattplace]

you can get tiny heli-coils. you would definitely get one for that bolt.

 

before you go that drastic, try an easyout with an 1/8" hole so you dont risk damaging the threads. you could try and heat the casting whilst turning the easyout and tapping the top of the easyout with a hammer (gently!)

[cosworth]

try tacking abit of weld on the old bolt then weld a nut on it usaully works for me.

[mikecotterill]

Cheers guys I've got a new bolt, it comes as one with the collar I actually thought it'd just come out and I'd lost it.

 

I had thought of an easy out but have never had any luck with them, might see about welding something on but don't want to damage the casing. Cheers again.

[weldersunited]

Cheers guys I've got a new bolt, it comes as one with the collar I actually thought it'd just come out and I'd lost it.

 

I had thought of an easy out but have never had any luck with them, might see about welding something on but don't want to damage the casing. Cheers again.

 

Hi Mate, the welding option is a great idea.... if the surrounding metals are steel as well. Think you have an aluminium casting there. If you weld the nut to the broken stud, the alu can tend to melt in the threads making the broken stud impossible to unscrew- I'v had this happen so speak from experience!

 

As other have said, try stud extractors, centre dot the broken stud before you drill and go slowly a bit at a time, checking. That way you can alter where the hole ends up before you get too far!

 

Good luck with it!

[treequip]

Hi Mate, the welding option is a great idea.... if the surrounding metals are steel as well. Think you have an aluminium casting there. If you weld the nut to the broken stud, the alu can tend to melt in the threads making the broken stud impossible to unscrew- I'v had this happen so speak from experience!

 

As other have said, try stud extractors, centre dot the broken stud before you drill and go slowly a bit at a time, checking. That way you can alter where the hole ends up before you get too far!

 

Good luck with it!

 

It's worse than that, the alloy is high magnesium, if you aren’t careful it just disappears

[Boatbuilder]

I`d try a Dormer eze out

[spudulike]

An easy out is by far the best idea - try to drill it out as central as possible and that way if the easyout fails, you can open up the hole and re-tap it. I believe it is a T5 (5mm) thread.

 

If this fails, use a helicoil as a last option - done all three in my time - all work:thumbup:

[mattplace]

Like boatbuilder said, dormer make good easyouts. I've got some bahco ones which look identical and never break / wearout.

Tried to remove a broken bolt from an outboard engine for a mate a couple of weeks back with an easyout he bought from halfords.... Waste of time! I think it was made of chocolate!

 

Buy a couple of decent ones and they'll last forever!