What it takes to remove broken bolts in a turbo

[TurboTdr3.8]

I thought this was 3 great movies of how to repair broken bolts and turbo repair on the exhaust housings , this would be a nice sticky for how to do repair your turbo broken bolts , they are a little long but are very educational for what goes on at the machine shop that does repair and fixes on our goof ups at times . Enjoy

http://blogs.hotrod.com/how-to-remove-a-broken-bolt-like-a-master-machinist-85693.html#axzz2h4TMYvZH

 

[bison]

The best advise I could give to anyone trying to extract any seized fastener that is broken off flush is to find a machinist to do it for them. A broken fastener is nothing. A broken faster that has an extractor broken off inside it is a much bigger problem. Also an incorrectly drilled broken fastener could be a problem. A drill should not be used to attempt removal. Properly sized end mill will have nearly a 100% success rate.


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[usetaboost]

Had a few break off on my old stock turbo. I had 3 that busted off. I would suggest anyone taking a stock turbo apart for the first time to heat the exhaust housing before trying to get the bolts out.

 

[sean lawrence]

that video was awesome!

 

[sean lawrence]

where was that track at?

 

[sean lawrence]

it sounded like a jet taking off!!

 

[Dunebilly]

nice video ...his shops in my town ....if I fail !!

 

[turbodave231]

If you want to try and extract a broken fastener, the very first thing is to drill straight all the way through the bolt or stud just like the guy the video says. Drilling thru the fastener relaxes the "press fit" The stuck fastener has in the hole. The second thing I try is heating the broken fastener (not the housing) near red hot with acetylene and applying paraffin wax. The wax works like penetrating oil and will work its way into the threads. This process works like magic. But sometimes, even the wax trick is a no-go. If you don't want or can't use heli-coils EDM might be a good alternative.

When the fastener is really stubborn, EDM will get it out.

If you break an extractor,Electro Discharge Machining will get it out

For broken bolts in anything where you can't use a lot of heat: EDM will get it out.

See a pattern here? Not every town has a good EDM service. We have lots of EDM shops in the Detroit area. My favorite shop charges $15 a hole for basic setups. They will not damage the existing threads and cleanup is easy with a standard tap......no heli-coils needed.

 

[Dunebilly]

I have a broken bolt inside the housing I'm going to just tap and drill it out its not stainless

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[Dunebilly]

15 bucks a hole ..lol I would that's a deal!! But really you spend more in personal time and labor than that doing it your self