Snapped Swivel Bolt

Putting my front axle together today and I managed to snap one of the bolts whilst putting it back on I took it all off and its sheared just inside the axle casing.

I have tried drilling holes, extractor kit, tap with a chisel, getting a mole grips on the thread on the otherside and just come in from trying to weld an M6 bolt in there but there isn't enough room to get a good bead (with an ARC welder).

Anyone got any other ideas? Its getting beyond the scope of my capabilities now so if there are any industrious folk in Bristol who want to help I would appreciate it! Im guessing a MIG might get a better bead in there to help it hold but there is little metal left on the end of the bolt itself.

The other option is to burn through drill bits and butcher it out and fit a helicoil of some sort but I don't know much about these.

Thoughts?

G

picture would help to get idea with what you are dealing with.

How about drilling into the bolt, tapping an opposite thread and then putting in a bolt to extract it whilst heating ?

I dont have a left hand thread drill bit but did try the extractors. These wouldn't bite into the metal though so were pretty much useless.

photos attached, looks like a bit of a mess in these!

I think I may have to keep drilling!

G

Is that a crack in the flange?

That'll teach ya to clean all threads thoroughly before re-assembly.
Those bolts should be loctited.

Probably be fine if put back together with 1 missing.

No, just a scrape.

All bolts were loctited.

Just butchered the sheared off bolt by drilling it.

Anyone else driving around with 1 bolt missing?

I was wondering if I could weld a nut onto the existing thread on the rear and draw it out that way? anybody done that?

G

Buy yourself a cobalt drill bit, drill it out and re-tap.

You may have to try some heat on it. A blowlamp is not hot enough. It needs to be glowing red hot to be of any use. Heat the protruding back end of the bolt with an acetylene torch flame and then get the mole grips on it.

Cant get the molegrips on the end shifty tried that. its too close to axle housing.

I may have to call out a mobile mechanic as my garage is limited to small tools really. most exotic thing I have is an ARC welder.

G

Fill the hole with weld and leave it out, not the best thing to do but will hold

That might have to be my last resort Sible :S

G

Griffdowg said:

Cant get the molegrips on the end shifty tried that. its too close to axle housing.

I may have to call out a mobile mechanic as my garage is limited to small tools really. most exotic thing I have is an ARC welder.

G

Click to expand...

Get a cheap pair of mole grips and grind the jaws thinner so they fit ??? Worth a try and if it dont work you're no worse off other than down one pair of grips.

Once the bolt is red hot you'll be surprised at how easy they turn.

Looking at the photos it looks that you have welded what was left of the bolt to the case...

could you get a stud in there, weld it on then use the stud instead of the bolt

Worse case just drill it out and use a longer 12.9 hex headed bolt and HT nut behind it. Yes you could leave it out but have seen axle ends stretch bolts after a hard landing. many of the comp safari guys just use 12.9 headed hex bolts and use a nut behind it.

Personally I'd drill out to as big as you dare before you get close to the threads and get a small ish strong punch and tap out the remains of the thread. if worse case take a little more out and use a longer bolt above with a nut behind as per the series axle ends.

that looks nasty mate, and it is always the hardest bolt to get to that snaps. personely i would keep drilling and re tap it may take a while but at lest you will know the job is done right.
try screw fix for heli coils if you need them. they do work fine. i have used many when i used to work as a fitter in my youth and since then with aliminuim bike engines.

Right, yes, the photo shows I have welded to the casing. Doh! I drilled that back off now though. Just had a chap around to try with a MIG but that did the same. Guess there is a better arc off the casing than the bolt!

anyway, I am now after an old swivel ball as I plan to use the flange as a guide to drill it out. I will then retap the thread hopefully.

Worst case is as Jai says, bugger bolt/nut. or Helicoil if all else fails.

Either way, could you all have a rummage around for an old swivel ball please

I kinda need it ASAP!

tried screw extractors, torx trick, drilled right through, welding an M6 into it. So it has come down to drilling it out.

thanks guys

G

have a look round for an axle, plenty about. easy enough to swap.

There is one in Chippenham for £100 on ebay but I really dont want to go down that route if I can help it. Would rather drill/tap this one as its only one bolt.

If I had 2-3 bolts snapped I would!

G

I have a front axle casing sitting in yeovil if you want it.