RE: Broken "Easy Out"

[bearbvd@domain.elided (Greg Hermann)]

At 10:57 AM 2/11/00, Simon Favre wrote:
>I agree. I'd try using a fine cutoff wheel to put a notch in
>the broken bit, then backing it out with a screwdriver. There
>are specialized removal tools with little teeth that fit into
>the flutes of drills & taps. The shops that do Electron
>Discharge Machining won't touch this?

EDM is the surest way to go.

Another approach:

Someone who KNOWS how and has a good touch can set a hex nut over the stump
in the hole and use a TIG torch to weld the nut to the stump down through
the hole in the center of the nut. The shrinkage from the weld will loosen
the stump a bit by pulling it inward away from the aluminium, With
practice, if you put a wrench on the welded on nut at just the right stage
of the cooling process, it breaks loose pretty easily, easy out, stump, and
all. Lots of WD40 and back and forth are appropriate once the stump has
moved a fraction of a turn (broken loose).

I have seen MANY rare motorcycle cases rescued with precisely this technique.

Greg

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