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Old 03-13-18 | 03:17 PM
  #6  
Ghrumpy
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Joined: Jul 2009
Posts: 786
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Originally Posted by SquidPuppet
Hahahahaha. What a nightmare. Worst case scenario. But I have good news for you....

I had the same thing happen to me on a brand new, freshly powder coated, expensive, magnesium, racing motorcycle wheel. I broke a brake rotor (defective ) bolt off. Drilled it, inserted the easy-out, turned, and SNAP. The was no other access than the front side, where I already tried. It would be a HUGE LO$$.

I called around and asked around among the racing folks, looking for suggestions for a remedy. Someone told me, "Just have it lasered out." I said, "What???". Unbeknownst to me, there is an industry for exactly that. Mostly for automotive engine applications, but a bolt is a bolt, and an easy-out is an easy-out. I found a place close to me and they lasered it out for $35.00. They let me watch. I gotta say, the precision of the machinery, jig, and process were fascinating. When finished, the cleaned up threads looked better than the factory threads.
Might be the same thing you're talking about but I've had broken extractors and bits removed with EDM (electrical discharge machining.) Cleans the threads completely and doesn't harm paint.
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