Stubborn exhaust bolt

[bashed]

I'm currently well into dismantling my T5 & have got the engine out & onto the workbench today. Hurrah!

I had a bit of an issue when removing the exhaust though. The bolt head snapped off when I tried to remove it, I had to cut the exhaust off. Now I'm left with a broken bolt which now seems to be firmly stuck in place. 







It's got WD40 on it & I've hammered it a bit, I've also tried heating it up. Please let me know if you have any ideas on how to budge it. Fitting a new exhaust might prove tricky if I can't move it.

Cheers, Neil

[bashed]

Pictures are not showing, so here's a link - www.dropbox.com/s/kab5psthk4fhooj/Bolt1.jpg?dl=0

www.dropbox.com/s/lt2d9gx2277kk7y/Bolt2.jpg?dl=0

[adrian]

Common problem 🙄 just keep spraying and apllying heat, if that fails you might have to carefully drill it

[adrian]

When you put it back together apply copper slip 👍

[bashed]

That didn't go well. 😡

I now feel like nicking a bell boys Scooter & driving it off a kerb.

Bolt still in situ, it simply won't move. It seems to be welded to the frame, I guess the heat from the exhaust expanded it & it became part of the frame. The bolt has a hole right through the centre of it, unfortunately, it isn't a straight hole, my drilling wasn't accurate enough. I'm going to have to find somewhere to remove it for me, then it'll need a bit of welding.

So, I'm back to asking for help here. What do I need to look for? Can anyone suggest what I should look for locally? I'm assuming I don't need a Scooter specialist shop, I just can't think who might do it.

Tia, Grumpy.

[gpowell]

Hopefully you are sorted
Get casing upright, make a plasteceen dam around the broken head to form a reservoir and fill with diesel and leave hopefully it will soak through
If you have threads left on the end, use a nut to draw the the broken bolt through.
Use some heat.

[scooterbooter]

Feel for ya there dude. That's the sort of luck I have. Normally specialists at that sort of stuff have a pun in their name about 'rusty nuts'.

[scooterbooter]

Probably cheaper for you rent some sort of cutting gear. Make a proper mess of it. Maybe not.

[bashed]

The worst thing is, I really thought I was drilling dead centre. The bolt end already had a shallow hole in the centre, so it was the perfect place to start drilling, I even used two nuts on the threaded part to keep the bit level.

I used the two nut method, reverse bits and plenty of heat & lube. One of my reverse bits broke off, this bolt is not going to move, I had to resort to drilling.

I'm going to try local engineering companies, hopefully one of them can help.

I refuse to let one Poxy bolt end my rebuild. There must be another way to mount an exhaust.

[ironsloth]

Keep drilling and use bigger drill bits. Then get a flat head screwdriver, and try to tap it round.

[bashed]

Yes, done that. There's only about 1 mm edge left at one end, reverse bit still won't budge it. That's not the biggest issue now though, the hole I thought was straight isn't & now I have a new hole. Somehow the bolt slightly diverted my drill bit the last third or so.
It's definitely time to pass the job on, I've reached the end of my skill level.

[gpowell]

Very difficult to drill straight with a hand held pistol drill.
Sounds like you now have lost any metal outide the casing hole.
An engineering company would be able to get it out, either by an induction heat tool or drilling it straight.
I have once in past put a cut through the casing under the bolt with grinder, this give some relief on the bolt and allowed me to get release oil the length of bolt, eventually was able to drive the old bolt out. I then welded the cut up. Drilled the bolt hole slightly bigger, used lots of copper grease on reassembly.

[bashed]

I think this is the answer. I'm sure someone else will have a similar problem and be googling an answer like I did. So, if you are looking for how to remove a very stubborn rusted bolt that had welded itself to your Vespa engine casing and you've tried everything else - heat, anti clockwise drill bits, two nuts tightened against each other & drilling out but it's still stuck, the answer you need is in the comment above this one.

I'll get some satisfaction knowing that my failed attempt might just help someone else in the future.

[paulrobinson]

you could drill a hole in centre of the bolt go in about a inch then use a worm extractor for bolts do a google search plus give it a good soaking and heat ps the worm extractors are left hand thread so should undo it