Cylinder Head Bolt Broke

[Martin]

Good old Ezy out's if ever a tool was misnamed this would have to be the top candidate. Try tapping the Ezy out, you could also try heat do not force it. You definitely don't want to break it. However as Drut posted there are now drill  bits capable of drilling an Ezy out. Once you get it out you might just have to drill as large as you can, possibly use a dremmel and pick the remains out. Good luck.
Regards Martin.

[drut]

"Good old Ezy out's if ever a tool was misnamed this would have to be the top candidate."

My take: ain't that the truth.If it won't wind back out your problem has just multiplied.

[The Mighty Gryphon]

I have to apologize for not being clear.  The E-Z out didn't break, the damn bolt is still in there and no amount of heat, penetrating oil, or banging on it will make it budge. 

I have broken E-Z outs before, and chickened out on this one before I broke it.  No way I'm going down that road. 

I am retreating for a couple days to think about this.  It looks as if the heat has drawn the temper of the bolt unevenly, and the drills are starting to run off center.  I haven't messed up the threads too much yet, so it looks like I might be spending some quality time now with a rat tail file truing up the hole.

Sure glad it's not too cold out in the garage yet.  Even more glad that this is not happening during riding season.

[drut]

"Sure glad it's not too cold out in the garage yet.  Even more glad that this is not happening during riding season."

Pleased for that:hope it works out well for you without too much hassle!

[Martin]

Gryph if you have access to a dremmel or a pencil air grinder, it is possible to carefully grind out the bolt. You need to grind it thin enough to pick out the remains, you just need a steady hand and nerves of steel.After grinding you then chase out the thread with a tap. I'm sorry you are having so much trouble.
Merry Xmas anyway Martin.

[The Mighty Gryphon]

Martin,  I have a Dremel, and even thought about using it, but unfortunately, the bulk of what needs to be removed is beyond the reach of the bits available to me.  There is a 7-8mm counterbore, and the threads continue another 30mm.  The rat tail file looks like the only, albeit, time consuming, option at this point.

With an unevenly tempered hardened bolt broken off in an aluminum block, I am increasingly becoming aware of the fact that there is a Helicoil in my future. 

[Martin]

Gryph to save yourself a lot of work you could extend the shaft of the dremmel bit by welding (Brazing)on an extension. I have done this with drill bits so it could be possible, although due to the RPM you would have to balance it. You would also have to go slower, due to the length of the shaft, but maybe you could sleeve it. It would be a lot faster and easier than a rat tail file. Just a thought but might be worth a try.
Merry Xmas Martin

[The Mighty Gryphon]

One of the things my garage is missing is a welder.  With most of the bolt drilled out now, it will probably take longer to get a welder than to file the remaining bits out.  I like to think I would have more control over a file than the Dremel down in that hole.

[Martin]

Christmas morning in 0830  OZ 20c cool, Gryph if you ever need to weld you can silver solder with a propane torch. You could put a late order to Santa for a MIG for Xmas, but only if you've been good. Will be having traditional OZ Christmas barbecue for lunch.
Merry Xmas and happy filing Martin.

[johnny]

this is how to weld with motobrick batteries and some jumper cables...

[Martin]

Johnny thanks for the video, I will now start carrying three deep cycle batteries and a set of jumper leads, a welding helmet and some electrodes. I can now earn extra cash as a mobile welding business. Do you require a commission if so what percentage, or I could just give you my Grandmothers recipe for Xmas Koala Pie :hehehe
Merry Xmas Martin

[Martin]

Johnny if you are interested in home made welders there are quite a few sites on how to make an alternator into a welder on youtube. Interesting, but a bit hard to mount on a brick.
Merry Xmas Martin.