Hi all,

Apologies for bringing a non-S2000 problem to the table but I'm really reaching the end of my tether with my Skyline.

Unfortunately it has a snapped flywheel bolt (clutch problems led to the gearbox being dropped which highlighted missing bolt head) also the bolt is really tight as I learnt after last changing my clutch that my torque wrench was over-tightening stuff massively which isn't much help either.

So far;

Drilled 3/8 hole into the Bolt (after drilling smaller pilot hole) to try and use an easy out - Hole was drilled off centre (don't blame friend too much, hard to do under the car!) and the easy out was biting into the crank. Then tried a straight flute extractor from snapon which looked more promising but looked more likely to snap the extractor than turn the bolt (possibly catching the crank? - thinking of trying this again with my impact wrench...)

After this I tried drilling a smaller hole further in to use the next size down straight flute, drilled a 1/4" hole but the straight flute extractor just doesn't seem to grip, maybe not deep enough but I've run out of bolt really

Specialist bolt removal guy could take a look for me but it'll cost a few hundred pounds (he needs to travel 75 miles to me for starters) and will need to either take the engine out first (alot of work) or find a garage with a ramp which I can use which just sounds expensive as would no doubt need to pay them for the pleasure also

Only idea's I've got are to try the 3/8 straight flute extractor again and use the impact wrench (assume it wasn't stuck on threads and is just that the bolt is tight is why I couldn't turn it before) or to try and find new tools which I can try such as the multi spline things from Snap-on;



Frustrating though as for example that tool is £3.50 odd but £6 delivery plus vat (more of it on delivery than the part) means that trying anything else adds up rather quickly!

Pics of the snapped bolt;





Any input/advice greatly appreciated

Cheers,
Alex

Edit: Sorry should have put this in Non S2000 car talk presumably

 

Hmmm, having been in a similar situation with a lower control arm and a seized bolt my solution was to drill out the bolt to the edge of the threads and then to knock the bolt in on itself. Then I was able to get the shock out which gave me the focus point of the seize (i.e. the threaded bolt into others) applied heat and lots of it and out it came.

From the pictures it looks as if you can drill out the bolt to weaken it, you can chip it out?

 

If you've already drilled the bolt off centre then you've got a very difficult task with the engine in situ to get that out.

Without the proper kit its going to be very hard to get the hole back in the right place.

I'd try to drill the remaining metal of the bolt out so that you just have a wisp of thread left and then collapse it. You'll have trashed the tread in the crankshaft doing that so i'd then drill it larger and helicoil it back down to the correct size.

 

Stick a bolt in there that is a leaves you a couple of mm play and see if you can MIG weld it to the outer shell of the stuck in bolt. The heat should help loosen it too. Bearing in mind spot welds only as you'll want to avoid too much penetration.

If you aren't confident, you can try the same procedure (smaller bolt) but pack the hole full of metal putty and squeeze the bolt in (a reverse threaded bolt would be better here). Leave it to set and you may get enough grip.

 

My preference would be to drill it out to the next oversize, then use a helicoil or a timesert or similar. To do thus, you need to be centred properly on the hole, preferably using a pillar drill...

Alternatively, once you get the flywheel off, if there's any of the bolt standing proud of the crank, you could use a stud extractor?

Sent from my HTC One X+ using Tapatalk

 

Put a nut over the top, MIG weld through the middle of it to the remains of the bolt, the heat will free it off and use the nut to take it out.

 

That's how I've done it in the past too but does he have too deep a hole? Can't tell from pic