My little dilemma...

**Pierce** · 28th November 2008, 11:00

Received my front forks back from Greg at Pro Ride suspension yesterday which is mint. I was bolting on the front brake caliper when the bolt snapped off while tightening it... Now I have the end of a bolt stuck in there that I can't get out.

How would you resolve this?

Any help would be greatly appreciated

Oh and I was doing it to the specified torque setting listed in the manual

**Danger** · 28th November 2008, 11:03

Just drill the bolt out through the center with increasing size drill bits, you might find that it actually winds its way out. You might be able to drill it from behind which makes the chances of it coming out even better. Otherwise you may need to use an ez out.
That bolt must of been over tightened at some stage or your torque wrench is out.

**Waihou Thumper** · 28th November 2008, 11:09

Originally Posted by Pierce

Received my front forks back from Greg at Pro Ride suspension yesterday which is mint. I was bolting on the front brake caliper when the bolt snapped off while tightening it... Now I have the end of a bolt stuck in there that I can't get out.

How would you resolve this?

Any help would be greatly appreciated

Oh and I was doing it to the specified torque setting listed in the manual

Try a little groove on the head with a hacksaw, then use a screwdriver or try and create a groove using a hammer and screwdriver.
Easy out, should do it as you can get big ones for bolts. I had something similar happen and ended up doing just that and getting a jewellers screwdriver, banging it in and unscrewing it.....
Same principle but on a smaller scale, this was a Fork Bleeder Valve that snapped off....
Good luck!

**Pierce** · 28th November 2008, 11:15

Torque wrentch is near new so i would hope its not out. My guess is the bolt has been weakened by over tightening by someone in the past. Will have a blast today... bloody pissed me off, there is always something that goes wrong Grrrrr

**mattwood** · 28th November 2008, 11:20

yeah, just tap a screwdriver into it gently and screw it out. It worked for me when i snapped my sump plug off

good luck

**Danger** · 28th November 2008, 11:23

Make sure you are reading it correctly ie not confusing ft/lbs with nm/kg. The best ones to use IMO are the simple cheap wrenches with the direct read off the dial. They don't go out of calibration and last for ever.

Do you want to bring it around for me to have a go at it?

**Pierce** · 28th November 2008, 11:26

Originally Posted by Danger

Make sure you are reading it correctly ie not confusing ft/lbs with nm/kg. The best ones to use IMO are the simple cheap wrenches with the direct read off the dial. They don't go out of calibration and last for ever.

Yeah i think it cost me round $250. I always use it in lbs as it's easier to get the right setting on there.

**Danger** · 28th November 2008, 11:34

You might not have seem my edit, so if you want to bring it around for me to have a go at let me know.

**Pierce** · 28th November 2008, 11:47

Originally Posted by Danger

You might not have seem my edit, so if you want to bring it around for me to have a go at let me know.

Ah you'rea top man Greg. will give it a whirl and if no luck call you. I appreciate it

**Danger** · 28th November 2008, 11:49

Good man for giving it a go! Start with a small drill bit, make sure its right in the center and drill straight all the way through the bolt. Then go up a few sizes. Once you have a pilot hole any drill bit that might grab the bolt might just wind it out for you. Hopefully you didn't use locktite? If so as you go up in sizes you could try pouring a jug of boiling water over it which will soften the locktite. You don't want to go so big in drill bits so that you drill out the threaded portion of the caliper so be careful but in my experience the bolt will usually come out pretty easy before getting that far.

**Reckless** · 28th November 2008, 11:54

You could use an ezyout which is the correct tool for the job.
I think I got my CK set from Bunnings. Not top quality but handy to have around.

Shouldn't be to hard as you've just had it out and they only do up to about 10-12 Ft-lbs I think??? Guessing thats what Danger will use??

**Danger** · 28th November 2008, 11:58

I've used ez outs before when I first left school and was a mechanic in a shop but since then I've never had to use one due to most bolts coming out with drilling or just not snapping any over my life time. You still need to drill a hole. So I don't have any here but they can be gotten easy enough if drilling doesn't work. Waitemata Hydraulics and Engineering would have them for an 8mm bolt.

**Reckless** · 28th November 2008, 12:16

Yeh either way is ok whatever works I guess. i'm sure you'll fix it quick enough for him.
And your right you still have to drill it first.
Just didn't know if Pierce new about the Ezyout alternative.
LOL! As you can see I've broken the ones he needs anyway.