Bolt just broke in half in the brake boss of new fork.
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Bolt just broke in half in the brake boss of new fork.
I got my new fork cut and prepared the other day and was just installing it. I was screwing in the bolts that hold my vbrakes on and one of the bolts just broke in half right at the brake boss. All but about 5mm of the bolt is now stuck in the fork. I was using a small hex wrench to do this, so I am guessing the bolt was somehow defective since I don't think it would be possible to generate enough force to break it normally. Is there anyway to get this bolt out? If not will I be able to replace the brake boss? The fork is a 2003 Rock Shox Duke XC UTurn.
Thanks.
Thanks.
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Could try getting a dremel with a small bit and try engraving a slot into one end of the bolt and unscrewing it with a regular flat-head screwdriver?
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Originally Posted by robertsdvd
Could try getting a dremel with a small bit and try engraving a slot into one end of the bolt and unscrewing it with a regular flat-head screwdriver?
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Yes, if it was that crappy that it stripped, DO NOT slot the head. As soon as you apply force with a flat head it will just strip. If there is enough bolt sticking out, soak it in penetrating oil (GT85, PB Blast), wipe the threads clean, and lock a small vice grip on the end sticking out. Slowly start applying pressure to back the screw out. no sudden moves or its easy to strip whats left.
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Get an easyout from the hardware store. Sounds like exactly what you need.
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Originally Posted by seely
Yes, if it was that crappy that it stripped, DO NOT slot the head. As soon as you apply force with a flat head it will just strip. If there is enough bolt sticking out, soak it in penetrating oil (GT85, PB Blast), wipe the threads clean, and lock a small vice grip on the end sticking out. Slowly start applying pressure to back the screw out. no sudden moves or its easy to strip whats left.
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I know it broke, but if the metal was weak enough to break under the sheer force of a small allen wrench, the head with strip if you slot it and try to back it out most likely. you might get an easyout to work but I don't know if they will work on anything that small.
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For as easy as it broke, this thing is quite strong... I tried drilling it and got no where. I tried slotting it, but it isnt going anywhere either. The brake boss has gotten quite hot now. Even if I get enough of a slot in the bolt has probably welded to the the boss now. An easyout isnt an option if I cant drill the bolt... Anyone have any more ideas? I could use this as an excuse to get disc brakes, but then I would need new wheels as well. That is just too expensive.
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wow. hmmmmmmmmmmmmmmmmmmmmm.............
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Originally Posted by bg4533
For as easy as it broke, this thing is quite strong... I tried drilling it and got no where. I tried slotting it, but it isnt going anywhere either. The brake boss has gotten quite hot now. Even if I get enough of a slot in the bolt has probably welded to the the boss now. An easyout isnt an option if I cant drill the bolt... Anyone have any more ideas? I could use this as an excuse to get disc brakes, but then I would need new wheels as well. That is just too expensive.
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Originally Posted by slvoid
Easy out I say! Or disc's...
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You have to ask yourself... Do you *Really* need brakes?
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Originally Posted by slvoid
You have to ask yourself... Do you *Really* need brakes?
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Hehe have you asked the LBS?
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Originally Posted by slvoid
Hehe have you asked the LBS?
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jb weld an allen wrench to it then turn after a couple of days.
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Originally Posted by slvoid
jb weld an allen wrench to it then turn after a couple of days.
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There's supposedly a story about a tractor with a cracked engine block that was glued back together with jbweld epoxy and continued to work for 10 months. I'm not sure what the shearing strength of the epoxy but its worth a try. Just drown the whole thing in wd40 or some kinda penetrant to try to loosen it up first.
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I try not to bring up experience to often, BUT, I have been a mechanic for twenty(20) years. Take this to someone that is experienced(This does not always mean a bike mechanic, a machine shop may be better) and have them remove it. If it broke on install it will probably come out without to much trouble but it is still best to pay someone that has removed a broken bolt 400 times rather than take the advice of a person that had a freind try it once.
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Originally Posted by bg4533
I got my new fork cut and prepared the other day and was just installing it. I was screwing in the bolts that hold my vbrakes on and one of the bolts just broke in half right at the brake boss. All but about 5mm of the bolt is now stuck in the fork. I was using a small hex wrench to do this, so I am guessing the bolt was somehow defective since I don't think it would be possible to generate enough force to break it normally. Is there anyway to get this bolt out? If not will I be able to replace the brake boss? The fork is a 2003 Rock Shox Duke XC UTurn.
Thanks.
Thanks.
#21
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Originally Posted by bg4533
For as easy as it broke, this thing is quite strong... I tried drilling it and got no where.
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Originally Posted by Raiyn
Yes the brake boss is replaceable. I have the exact same fork and I removed my bosses when I mounted disc brakes. (Although now I can't find the flippen' things.)
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As a machinist I would guess that it would be cheaper to replace the boss then to have a machine shop get it out. I have never tried the JB weld idea but it sounds like it might work if you put a little on the end of the allen wrench and were careful not to get any in the threads. The hard part would be finding a way to hold it steady until it dries. Also if you are using a drill or dremel and it heats up let it cool down before trying to back it out. The heat will cause it to expand in the hole.
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Originally Posted by bg4533
What did you or anyone else here use to remove the bosses? I tried using an adjustable wrench on an old fork and it had just enough flex in it to strip the head.
I thought this was a universally known fact <sigh>
NEVER USE AN ADJUSTABLE WRENCH IF YOU CAN HELP IT
If I remember properly it was a 9mm open end wrench. Take it to a Bike Shop NOW before anything else goes wrong.
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Originally Posted by Raiyn
I thought this was a universally known fact <sigh>
NEVER USE AN ADJUSTABLE WRENCH IF YOU CAN HELP IT
If I remember properly it was a 9mm open end wrench. Take it to a Bike Shop NOW before anything else goes wrong.