Broken bolts suck. Especially when you know you have one but can’t see just how bad it is because the part it is supposed to be holding on is still in the way. You know, like when you break the back exhaust manifold bolt off in an LS or Big Block cylinder head. If you are lucky, you pull the manifold off and find that the bolt has broken off flush, or just above or below the surface of the head so that you can put a nut over it and weld the stud to the nut. If you are not so lucky then the damn thing is broken off way inside the hole. This is when the normal drill, use an extractor and fail, drill it even more aggressively, and ultimately get it out after jacking the threads up. Or you break a bolt extractor off in the hole and feel like a better way to start your day would have been to smash your thumb in a vice and then use a ball peen hammer to beat the rest of that hand into a pulp.
But it doesn’t have to be that way. Some patience, and a few tips and tricks, will make the removal easier or at least more successful. I have heard of using a self centering drill bit, like those used on hinges and such, but I had never thought to drill out a bolt to use as a drill guide. That one was new to me. But watch this video and you’ll see a few cool ones to try. I think there are some great tips and tricks in this video, so watch and learn.
If you have any great shop tips or tricks, let us know!