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Busted Bolt Extraction

To: mgs@Autox.Team.Net
Subject: Busted Bolt Extraction
From: Matt Kulka <Matt.Kulka@hboc.com>
Date: Mon, 09 Mar 1998 17:07:11 -0500
t rained all day Saturday, and my wife had her mom to visit with, so I
had some time to start putting the motor back together on my '74 B. 
Crankshaft and main bearing caps went in without a hitch, and the new
shallow dish pistons gleamed beautifully from freshly overbored
cylinders.   Next step, the new camshaft:   Pre-installed the sprocket
to check the endfloat, glooped lots of lube on the bearings, inserted
the shaft carefully so as not to ding a bearing with a cam lobe, found
the correct position for the retaining plate, started twisting in the
1/4" bolts, and then zzziippp! Twisted a head right off one of the
bolts.

I tried to grab it with a vice-grip, but there wasn't enough bolt
sticking out to get a grip on.  Next step, I drilled a hole in the
middle of the bolt, inserted a screw-extractor, gently tapped it with a
ball peen to set the threads.  Connected a tee-handle, gently applied
pressure, felt the threads take a bite, added more torque, and then
piinnngg!  The screw extractor broke off in the bolt.

Now I have a real mess.  If I'd have left it alone, I could have drilled
the whole mess out oversize, and installed a heli-coil.  But I don't own
a drill bit that can chew into the hardened metal of a screw-extractor. 
I know, because I tried.

If any of you old hands or slick whippersnappers can help me out here, I
sure would be grateful.  I'm plumb out of ideas (and the ones I had sure
didn't do me much good.)

Thanks in advance.

Matt Kulka
'74 B - whose life is dangling by a thread.

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