Broken water pump bolt in block, any ideas?

[Rick Piras]

I was assembling parts onto the small block motor going into the Chevelle and one of the water pump bolts bottomed out and broke off flush with the block. No problem, right? It's a 3/8-16 bolt so I get a #3 easy out, drill a nice hole in the center of the bolt, drive the easy out into it, mount the tap handle, and break off the easy out flush with the bolt which is flush with the block. CRAP! I went out and bought the best hardened drill I could get, but it has NO affect on the equally hardened easy out. I've also tried drilling a small hole into the bolt (between the easy out and the block) and trying to use a punch to "drive" the bolt counterclockwise with a hammer. No luck! Any ideas at all?:pat:
P.S. The motor is on a stand so I have good access.

[jy211]

do you have a welder? If so try and tack a new bolt to the broken off one since it's flush with the block????

[6'9"Witha69]

do you have a welder? If so try and tack a new bolt to the broken off one since it's flush with the block????I have seen this work several times before.

[Jim68nC]

I've had the exact same thing happen in the past. At the time I didn't have a decent welder to try that. (good idea) I also couldn't find a drill bit that would have an effect on the hardened easy out.

I ended up using several cheap diamond flaked (so they called them) miniature hole saws for like dremels and ground the bolt/easy out between the block and easyout. I worked that bolt for way too long and messed up the first cpl threads trying to get a bite on it with a chisel but eventually just kept working it unil got it all out. Sucked, but the remaining threads held and sealed up fine. The diamond tipped cutter/grinder points were found at Harbor Frieght, I'm sure there are better out there but that's what I had available at the time. If I had more paitience I'm sure I could have ground/cut on it with a little more precision but you know...:machine:

Anyway, just a different approach if the weld idea doesnt work for you. I know that sucks...I hate easy outs now...(I blame them not me for breaking the bolt of course)

[69c4x11]

You can buy Welding rods for extracting broken bolts,,, Xergon is one manufacturer.. They work Great !!! This job would be for someone with experience,, not for an novice,,,, An other suggestion is left handed drill bit ( reverse flute) they also work great !!! Hope this info helps

[Rick Piras]

Thanks very much for the suggestions. I was able to borrow an arc welder from a buddy in facilities. He gave me a quick lesson, and let me try some practice welds before I took the welder. Being my first time at welding, and having very limited access to the bolt, the weld (surprise!) failed. The same buddy suggested something similar to what Jim68nC recommended so I tried that next. So far I've only gotten enough material from between the easy out and the block to where I can get some sideways movement on the easy out if I hit it with a hammer and punch. But that's a moral victory. I'm beat and going to bed, but it looks like this will work, and I'll have to retap the threads. Thanks again for the ideas.:rolleyes:

[Bill68fbrd]

I have had to use a machine shop with a spark eroder then had to install new thread Recoil.Good luck

Bill

[Madspeed]

The way i have allways removed broken bolts for the past 18 years or so is this

Take a washer (if 3/8" bolt then 3/8" washer) put the washer centered over the broken bolt (if its flush or below) take a mig weldor and weld the ceter to the washer from CENTER out.
this heats the bolt Really hot and losens it a little And allso gets better penetration into the broken bolt.
Next take a nut (if 3/8" bolt then a 3/8" nut) place this nut over the washer you just flushwelded over the bolt and weld the CENTER out to the nut, I like to spray some w/d40 or triflow (your fav spray lube should help) While its hot, sometimes if it breaks ill redo it and while its hot I will use an icecube on the nut to cool it fast and shrink it while leaving the threads hot and swollen next take a wrench or sockett or whatever you want to turn the nut.
Turn the nut as litle as you can loosen then tighten, repete untill it loosens up and comes out.

If the nut breaks off then just reweld a new one and repete.
Same trick if its broken stiking out but then id either weld a nut to the nub or weld up exra metal to the nub untill i can get visegrips on it
I have NEVER had to drill a broken bolt or EVER use an easy out after I learned this trick.
Almost every easyout I have ever used has broken b4 removing the bolt (Not so easy are they)

b4 this trick i used to just drill out the bolt and pick out the threads then run a tap through it

I used to work at a VW shop when I was 16 and I Was the One who was voted to remove all broken exaust studs =)

[copo69]

just go to the local hardware shop get a nice easy out drill the old broken bolt and twist it out with the easy out . careful as the iron block is softer than you think..

[Madspeed]

Untill the easy out breaks=) then your really F'D

[indyjps]

im done with ez out's, ive taken square bar stock and tapered the tip, inserted that into the bolt and driven it in, that way if it breaks youre not trying to redrill hardened steel. also torched the bolt and run wax into it instead of wd40. just take a flat blade screw driver and let the wax run off the candle down the screwdriver onto the bolt, as it cools it draws the wax in like solder then just chisel and hammer it. we break a lot of bolts off @ work and welding is the best way if its accessible.

[VenturaII]

I tried O6T'rex's way. Worked like a charm.