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Old 03-05-2015, 10:39 PM   #9 (permalink)
Zipper 104
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Location: Canada's Wet Coast
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Default EasyOut

Use a file to get the surface as flat as you can (if you have the space)) so you can get a centerpunch to mark a spot for the tip of the bit so it's less likely to wander. You don't want to drill a hole that will remove too much 'sidewall of your new hole, mess with the threads your bolt is in, nor drill right through. (you don't want the cuttings to go down where they might present a bigger issue than a snapped off bolt head) You'll need sidewall for the EO to grip. Pick up a small set of Easyouts and find one that you are able to get in a ways before it starts gripping the wall of the hole in your bolt. (you want it to grip tight before it bottoms in your hole) You'll get it tight with a slight tap of a hammer. You must need to leave sufficient 'sidewall' in the bolt for the EA to grip enough but not blow the remnants apart. You put a wrench on the end of the EO and turn it out. (they have a square top) They're slick. You might pre-treat the bolt with some Deep Creep or Loosenall or whatever first, and I suggest you use some cutting fluid when you drill the hole.
It may very well be cross threaded. If that's the case that'll give you the opportunity to work with Heli-Coils.
And make sure to get the sparkplug hole plugged before you start. You don't want crap to get down in the cylinder if it's so close you wanted it out to get to the SP.

What's this 'bolt' for?
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