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blimbug

Member Since: 17 Mar 2016
Location: Wiltshire
Posts: 92

2009 Defender 110 Puma 2.4 SW Bonatti Grey

That "oh cr#p" moment...

So, I purchased some tasty security bolts recently (since mine were looking a little rusty), going great (replaced the rear door hinge bolts etc) until I got to a rather stubborn bolt on the tub.

Easing it out gently until, oh cr#p, it's sheared off and left half the bolt shaft in the hole...

Anyway, I'm guessing the best approach would be to try and drill out the remains, starting with a small drill bit and gradually getting larger.

Any hints or tips of the best way to approach it?

19th Nov 2016 9:16pm

JAY BOY

Member Since: 04 May 2010
Location: Not here
Posts: 1706

I would give it a large dose of WD40 over night and drill the centre out. Insert a stud extractor and it should come out.

19th Nov 2016 9:19pm

Romadog

Member Since: 07 Jul 2011
Location: Powys
Posts: 1751

Done exactly the same today.
As you said just drill carefully gradually increasing drill size.
Use hammer and punch to crush bolt inwards - just to break seal with captive nut.
Then use mole grips to slowly unwind.
Copious amounts of WD-40 required throughout the process.

19th Nov 2016 9:21pm

blimbug

Member Since: 17 Mar 2016
Location: Wiltshire
Posts: 92

Ah, feels a little better knowing I'm not the only one that's done it...

Just ordered a stud extracting kit on Amazon - don't you just love prime, delivered tomorrow (hopefully early enough that I can get it done tomorrow).

19th Nov 2016 9:35pm

shaggydog

Member Since: 12 Aug 2012
Location: Kent
Posts: 3347

1991 Defender 110 200 Tdi USW Arles Blue

Another good way to remove a headless bolt.

Left handed drill bit, drill in the centre the gentle heat from the drill helps crack it off and the anti-clockwise rotation helps unwind the bolt Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197

Self confessed mileage hunter

19th Nov 2016 10:12pm

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