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Thread: drilling out a easy out. Help

  1. 20th July 2013, 07:30 PM #1
    Tassie Hang Over's Avatar
    Tassie Hang Over
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    drilling out a easy out. Help

    Okay guys We (Meaning me and my brother in law and beer) have broken a easy out in a stud on the manifold, Any tricks to drilling it out,

    Should of stuck to drilling and retapping it, But no we thought we would give that a go, For some sill reason
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  2. 20th July 2013, 07:35 PM #2
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    with a very sharp requenched chisel see if you can tap it in the normal direction of do up and work it out...

    gently warming the whole area then quenching the eazy out with freeze'n'release may help

    failing that its time for spark erosion because really, you cant drill an ezy out.
    Dave

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  3. 20th July 2013, 08:13 PM #3
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    Not sure why they are call easy outs really, if the bolt was going to come out easily, you wouldn't need one and by the time you do, you can easily break them.

    I've done this myself, but been lucky enough for a bit to be still protruding from the hole, and have been able to get vice grips on it to get it back out.

    I find it easier now to drill the stud out and put a helicoil in.

    Hope you manage to remove it.
    If you need to contact me please email homestarrunnerau@gmail.com - thanks - Gav.
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  4. 20th July 2013, 08:18 PM #4
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    Easy out

    You could try a cobalt bit.

    Use penetrene first.
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  5. 20th July 2013, 08:32 PM #5
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    "Easy" outs

    You've discovered the Rule of Advertising. They ain't.
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  6. 20th July 2013, 08:43 PM #6
    ADMIRAL
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    You have no show drilling it out. The drillbit will gravitate to the softer metal around the easiout, and increase the mess. I would think using heat in an attempt to retemper the steel, or trying to weld something to the end. It may come to taking metal off the manifold to allow access to the easiout. Can you remove the manifold? If possible, remove and take it to a specialist. Some of the exhaust guys are whizzes at this sort of thing.
    D4 2.7litre
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  7. 20th July 2013, 08:47 PM #7
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    Depending on the size of the easy out compared to the stud, I have successfully drilled a series of small holes around the easy out. If you are able to drill close to the easy out and very close to each hole then the easy out almost falls out.
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  8. 20th July 2013, 08:55 PM #8
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    45yrs a fitter.....I can only smile, sorry, I believe drilling /tapping/use of thread extractors is a specialised job. I have seen it happen so many times...broken taps...broken easy outs.....get an expert from here in mate.
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  9. 20th July 2013, 09:11 PM #9
    Bigbjorn
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    The short answer is you can't. You should have never have used one. They are tapered and force tightly into the drilled hole in the broken stud and wedge it tighter into the female thread.

    You can drill them with a tungsten carbide drill but you need a rigid set up that will stop the drill wandering off into the softer metal of the broken stud.

    Best bet is to use a left hand drill rather than an easy out.
    URSUSMAJOR
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  10. 20th July 2013, 09:27 PM #10
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    I broke two of the bastard things when doing the exhaust manifold on the td5. Had to get a specialist in, who's job it is to do this very thing around the workshops of Perth, it's all he does. He does it freehand and uses a small air gun having to sharpen the bit every couple of minutes! Took a good while to do but he got them.
    Sorry doesn't really help but it can be done!
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