Broke My Secondary Bolt Off!!! Pic Attached Help lol

[White-Powder]

So today I went to put my bolt back on to reinstall secondary and I mistakingly used my impact to tighten and it soon broke off inside the jackshaft. I have tried using my left handed bits etc to no avail...The bolt is broke off about a 1/4" into the hole so can't just grab on to it...When I tried drilling into it the bit moved slightly to the side and I am not sure yet if I messed up any threads on the jackshaft but IF I did, would I be able to rethread the hole or use a helicoil for this repair? New jackshaft costs me $289...This is a 2015 IQR stocker I plan on racing this year...Any help much appreciated!

 

[SRXSRULE]

So the bolt is not cross threaded........it was just over tightened and twisted the head off?
Is the jack shaft steel or aluminum?

Before you go any further....DO NOT break an ez-out off inside that hole.

Are you GOOD with a Mig welder? I often remove broken off exhaust manifold bolts in cylinder heads buy welding a nipple onto the broken bolt and then welding a new nut onto the nipple to get it out. Welding helps "shrink" the stuck bolt and allows it to be removed.

Another good option would be to remove the jack shaft and take it to a machine shop. Putting it in a lathe would be the perfect option to insure its drilled dead center. You may even need to use a Mill bit instead of a drill bit to prevent it from trying to follow the off center hole you already drilled in it. Eric

 

[Hardass]

Since no locktite is used on that bolt you might get a small chisel and tap it out done it a few times before .

 

[White-Powder]

Unfortunately I don't weld at all but yes I know what ya mean. I m gonna have a guy from work come over after work and see what he can do... If all else fails and the jack shaft threads do get jacked up is it possible to rethread this without issues down road or am I buying a new jack shaft? The real problem I see at moment is I didn't center punch the bolt so my drill hole into bolt is off to one side which is why I'm concerned about getting into the threads...

Oh and no I don't believe it is cross threaded, I finger tightened it all the way, then two quick hits with impact

 

[White-Powder]

Forgot to mention, bolt broke off at start of threaded part of bolt, so 98% of the threaded part of the bolt is in there.

 

[snowmobiler]

looks ok.might come out easy

 

[LoudHandle]

The first thing to try would be a Left hand helix drill bit of the same size as the off center hole. In all likelyhood as the left hand drill bit starts to cut it will spin the remaining bolt right out. Then all you need is a quality grade 8 bolt as all the stock fasteners are "junk" grade 3 fasteners.

P.S. No self respecting mechanic uses an impact for assembly of anything.

 

[05900]

Bolts are like Jello...

Grab frosty beverage and a SHARP center punch, get it centered and start with a small ( left ) drill bit. Then work your way up if needed
You can save it.!!

 

[White-Powder]

I started with left hand drill bit but it wouldn't get a hole started for the next bit ti extract. That and not punching is how I ended up to one side. My problem right now is my extractor bits I have right now aren't the right size to grab it. So I have a different set to try tonight, well see what happens!

 

[kevinm7]

I've done this before on my old REV (although not with an impact). Take your time. Make sure you center punch the bolt, yes I know it's already been drilled. Start with the smallest bit you have and work your way up. DO NOT snap an EZ-Out off in the bolt. Those things are set up for a tap handle for a reason. Do not use a drill. I did that once on a master cylinder on my 450 and guess what, I got to but a new master cylinder.

 

[White-Powder]

Well after alot of drilling and trying it wouldn't come out so ended up drilling through bolt and rethreading and putting in the right length 3/8 bolt vs stock 5/16 so good as new now... What a nightmare. I'll never forget this lesson lol. Thanks for all the posts and suggestions!

 

[Norway]

Welding is your friend here. And if the size is not to small, use stick welding! The flux will settle into the threads preventing you from welding the bolt to tge shaft.
The chief welder where I used to work always brought some special sticks for these jobs, cant remember he ever failed.

Glad you gor through anyway!

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