how do i remove snapped bolt in roof rack nut?!!!

[Haysieboy]

I was fitting my roof rack to my '06 doblo cargo van when the fixing bolt snapped inside!! Anyway, I've got the gear for drilling/removing snapped bolts so got to work. Once drilled, the removal tool snapped inside! (I was being gentle... Honest)

Now I can't drill the removal tool out and its too far in to weld a new head on or cut a screwdriver groove in.

How do I go about removing the nut fixed inside the roof and get hold of a new one?

Haven't got the money to take it to a specialist, so home remedy instructions only please

 

[fingers99]

I've never known those removal tools to work, and they're too hard to drill out. Try firing MIG wire down the hole -- sure, you'll have to drill it out again, but it should temper the easy out enough to make it drillable.

Otherwise it'll be a matter of cutting into the panel (plasma disk?), replacing the captive nut and welding it all up again.

An alternative might be to find someone with a very steady hand and a plasma cutter.

 

[Haysieboy]

Oh dear... was hoping for an easier solution than that! The captive nut is surrounded in some kind of resin and was hoping it may be achored in place with that and I could maybe dig it out

It's snapped about 12mm below the surface. If I re-threaded it do u reckon that'd be enough to stop the roof bars ripping off half way down the motorway?

 

[fingers99]

I'd think so. If in doubt, pop a helicoil in.

 

[Andy Monty]

you tried drilling the stud extractor out with a colbolt drill bit?

once removed soak in Bilt hamber ferrisol and have another go (use the ferrisol as a cutting fluid whilst drilling too)

 

[rich2k9]

Hi guys
I'm new to the forum
I had the same problem but the cobolt drill bit snaped in the hole aswell... And had the bright idea of trying to rotate it out with a screw driver and hammer.. Result of that is that is its mostly fallen in to the second skin

Any ideas how I can get out of this one

 

[varesecrazy]

Hi guys
I'm new to the forum
I had the same problem but the cobolt drill bit snaped in the hole aswell... And had the bright idea of trying to rotate it out with a screw driver and hammer.. Result of that is that is its mostly fallen in to the second skin

Any ideas how I can get out of this one

how much is left of the broken bits..
brazing to it may give a chance of getting some debris out.., along with some decent soaks of plusgas etc..

then drill out a couple of stepped holes , and use this;
https://www.google.co.uk/url?sa=i&r...IHbT995SesLIwbJRH809j75Q&ust=1453918079613547

you hammer it in, the chisel edges grip the sides of the hole steps,
and you can put a decent size tap wrench on it..,
http://www.ebay.co.uk/itm/like/4007...ICEP3.0.0-L&ff14=122&viphx=1&ops=true&ff13=80
HEAT is always a good idea with things like this,
I tend to sweat things out.. with local heat, then release fluid, heat/repeat..!!.. then the tolerances break it free.

in my experience the helical ones are JUNK,

the U.S. Pattern - "knock-in" ones - are far superior , they don't SNAP either

 

[rich2k9]

There was the bolt and 2 HSS bits in there
The cobolt bit got most of it out but 3/4 inch of the cobolt bit in there

I'll take a photo and up date tomorrow as it is very wet and windy here

 

[rich2k9]

Fixed now had a new nut and washer welded in

Just need to grind it down then touch up the area

Thanks for the help much appreciated