Safety wire snafu

ithaca00 · April 21st, 2010, 04:09 AM

While drilling the oil drain bolt for my new race bike I snapped a drill bit in it. The bit (1/16") broke such that the bit is below the surface of the bolt head and I can't get it out. Is there a trick to getting a broken bolt out? Is there an option other than replacing the $25 bolt?

Thanks for any help!

Momaru · April 21st, 2010, 06:32 AM

A few ideas I've used at various times in the past for when I've botched a drill bit:

1/16" is pretty bleedin' small, but might try stuffing some stiff wire (paperclip?) in the flutes as deep as you can get it, and trying to back it out by twisting on the wire

Any chance of coming at it from the other side and tapping it out when they meet? Obviously this needs precise alignment or you'll wind up with misaligned holes that'll make it difficult to get the wire through without re-drilling it larger.

May also consider 'easy-outs' (or just some left-handed drill bits), counterclockwise threaded drillbits designed to help with this kind of problem. Finding one small enough might be a task, and I'll tell you from experience it really sucks when one of these breaks off on top of the item you're trying to extract, but that's generally rare.

And of course, any chance of simply taking the drain bolt to your local automotive (or hardware) store and finding a match for $2?

2WheelGuy · April 21st, 2010, 08:24 AM

Just leave it and drill another hole. The drain bolt is so big I like to drill at an angle through adjacent flats vs. straight through the whole bolt.

It takes a little practice. Without a guide you need to drill in about a 1/16" then start again at a slight angle, then again. Eventually you'll be able to go at an angle. It takes practice and patience but results in fewer broken bits.

Dmitriy · April 21st, 2010, 09:44 AM

I used a drill press, those bolts seem to drill hard-easy-hard.
I used a LOT of WD40 when drilling and putting only a little bit of pressure on going down.
I also came back up frequently.

If the bit broke in such a way that its blocking the center-line of the bolt then try craigs method. If the center is not blocked by the broken bit then you can drill all the way through one of the other sides.

Remember WD40 (lots of it), Drill press & go easy at the end.

rockNroll · April 21st, 2010, 09:44 AM

What 2wheelguy said...

ithaca00 · April 22nd, 2010, 11:12 PM

Ok, I'll try that next time Craig. I tried going at an angle but got nowhere. I then remembered the seized engine I have lying around

Greg_E · April 23rd, 2010, 04:21 PM

Might be worth a cheap milling machine so you can cut a flat spot on the corner for drilling. Cut all your flats, change to drill chuck and start drilling. The Harbor Freight Micro Mill is a decent little device for this sort of work.

April 21st, 2010, 04:09 AM	#1
ithaca00 ninjette.org guru Name: Ryan Location: Sacramento, CA Join Date: May 2009 Motorcycle(s): 2007 EX250 (street), 1994 EX250 (Race), 2008 250R (Race), 2000 250 (project), 1991 EL250 (a cruiser!) Posts: 287	Safety wire snafu While drilling the oil drain bolt for my new race bike I snapped a drill bit in it. The bit (1/16") broke such that the bit is below the surface of the bolt head and I can't get it out. Is there a trick to getting a broken bolt out? Is there an option other than replacing the $25 bolt? Thanks for any help!

April 21st, 2010, 06:32 AM	#2
Momaru ninjette.org certified postwhore Name: Paul Location: Roanoke, VA Join Date: Jun 2009 Motorcycle(s): 2008 Candy Plasma Blue 250R Posts: A lot.	A few ideas I've used at various times in the past for when I've botched a drill bit: 1/16" is pretty bleedin' small, but might try stuffing some stiff wire (paperclip?) in the flutes as deep as you can get it, and trying to back it out by twisting on the wire Any chance of coming at it from the other side and tapping it out when they meet? Obviously this needs precise alignment or you'll wind up with misaligned holes that'll make it difficult to get the wire through without re-drilling it larger. May also consider 'easy-outs' (or just some left-handed drill bits), counterclockwise threaded drillbits designed to help with this kind of problem. Finding one small enough might be a task, and I'll tell you from experience it really sucks when one of these breaks off on top of the item you're trying to extract, but that's generally rare. And of course, any chance of simply taking the drain bolt to your local automotive (or hardware) store and finding a match for $2? __________________________________________________ Proud member of the Blue Army

April 21st, 2010, 08:24 AM	#3
2WheelGuy ninjette.org certified postwhore Name: Craig Location: Silicon Valley, CA USA Join Date: May 2009 Motorcycle(s): '98 EX250, '02 EX250, '08 250r, '03 SV650, '98 GSXR750 '03 Hayabusa, '87 YSR50, '84 ZX900, +MORE Posts: A lot.	Just leave it and drill another hole. The drain bolt is so big I like to drill at an angle through adjacent flats vs. straight through the whole bolt. It takes a little practice. Without a guide you need to drill in about a 1/16" then start again at a slight angle, then again. Eventually you'll be able to go at an angle. It takes practice and patience but results in fewer broken bits. __________________________________________________ CraigHarris.org Pacific Track Time CraigsWeb See you at 2014 MotoGP Laguna Seca! We'll be camping on Fox Hill. AFM #278

April 21st, 2010, 09:44 AM	#5
rockNroll . Name: rock Location: greenville, south carolina Join Date: Jun 2009 Motorcycle(s): black Posts: A lot.	What 2wheelguy said... __________________________________________________ Always get a second opinion because most of these people are makin' this stuff up

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April 21st, 2010, 09:44 AM	#4
Dmitriy voda? Name: Dmitriy Location: Bay Area, CA Join Date: Oct 2009 Motorcycle(s): .... & a Ninja 250 duh Posts: 65	I used a drill press, those bolts seem to drill hard-easy-hard. I used a LOT of WD40 when drilling and putting only a little bit of pressure on going down. I also came back up frequently. If the bit broke in such a way that its blocking the center-line of the bolt then try craigs method. If the center is not blocked by the broken bit then you can drill all the way through one of the other sides. Remember WD40 (lots of it), Drill press & go easy at the end.

April 22nd, 2010, 11:12 PM	#6
ithaca00 ninjette.org guru Name: Ryan Location: Sacramento, CA Join Date: May 2009 Motorcycle(s): 2007 EX250 (street), 1994 EX250 (Race), 2008 250R (Race), 2000 250 (project), 1991 EL250 (a cruiser!) Posts: 287	Ok, I'll try that next time Craig. I tried going at an angle but got nowhere. I then remembered the seized engine I have lying around

April 23rd, 2010, 04:21 PM	#7
Greg_E ninjette.org sage Name: Greg Location: central new york Join Date: Aug 2009 Motorcycle(s): 90 Suzuki gsx600f Katana, 03 Buell XB9R Posts: 868	Might be worth a cheap milling machine so you can cut a flat spot on the corner for drilling. Cut all your flats, change to drill chuck and start drilling. The Harbor Freight Micro Mill is a decent little device for this sort of work.