Rusty Broken screw removal help.......

Working on my Way Cool Vented Windshield. I have it almost completely disassembled. I have three broken screws I can't get out.

It's the 3 screws that hold the windshield clamp on. One on the left and 2 on the right. The screws are broken off flush with the surface of the windshield. I've soaked them with PB blaster for a few weeks. I tried one of those Craftsman-drill-out-the-center and put in one of the screw extractor thingies. No luck. They bite and when I start to twist, they strip out.

Any suggestions? The screws are to small to weld something on twist. I thought about a torch and heating the broken screws but I don't want to screw something up. And with a torch, should I let it air cool or quench with water?

This being a vented frame, I don't want to screw anything up. Thanks............

 

If you know the size and thread pattern of the bolt you could drill the screw with the required bit size, if you do it dead center and go slow you can then run the tap and all is well, it will chase all the threads.

 

Good idea Snowwjob1. Unfortunatlly, the goofus that drilled the holes for the screw extractor drilled it off center. So that won't work.

But I might be able to tap the inside of the screw, thread in a small bolt with a nut already threaded on it and then tighten the nut down. Maybe even through drill the broken screw

I'll think of that. Good idea snowjob.......

 

Just do what Warloch said just start the small drill bit off center of the hole you alredy drilled

 

I feel your pain. I once broke the back exhaust manifold bolt off on an F head I had just re-installed and had to pull the engine back out to get to that bolt. Bolts are a little easier to use an easy-out on as you have more material to work with. Also, with a hole that's off-center, you don't get the proper leverage with an easy-out. Good luck and be patient.

 

If you keep drilling, slowly increasing the size, the threads will fall out even though its off centered. If you gradually increase the drill bits, you usually won't even have to retap the threads. I've had luck stopping right before the threads and whack the thin side with a chiesel.

 

:iagree: Even if the threads are off center if you keep drilling slightly larger holes as soon as one side of the hole meets the threads it will usually allow whats left of the bolt to loosen up because its not a complete circle anymore, The traditional easy out may work then. If you slightly disfigure 10% of the female threads with the drill bit it wont really hurt anything.
Patience is essential, have plenty of :stout: :tea: on hand and you will do fine

 

i would takea cutoff wheel, and carefully grind the screw below the surface. then useing a center punch, mark where the hole will be. next drill/tap.

another option: got to sears and get the screw removers (left hand drill bit type) and try agian.

next option: heat the screw and cool it with wd40 (no idea if others catch fire or not) couple of times then grap the end with vice grips and try to remove.


don't forget neverseize or you will be repeating this.

 

OK, I took the same size drill bit as the hole I already drilled off center, and through drilled the screw. Then I worked the bit up and down with the drill on to work the hole back close to center. Then I used larger bits until I had the orgional screw drilled out.

Problem was the threads still would not come out. So I went a size up in drill bit so I could drill out the threads that were full of the rusted together screw parts. Then I used a 1/4 - 20 tap and rethreaded the holes.

Problem solved. Thanks guys......

 

www.4grabit.com

 

Could a guy use one of those drill bits that run backwards? If your drilling it out anyway the reverse bit may bind and turn the screw out.

 

that would be the left hand drills. they work sometimes, the screw removers work best.