Broken extractor

Freakin' great....while trying to extract a broken exhaust manifold stud in my 440, I drilled a hole in it, and used a spiral extractor--that was technically too small for the stud--to back it out (I'm cheap..it was on-hand, but now I know I shoulda used a drive-in type)...sure enough, the damn thing broke off in the stud. Now I've got a hardened extractor stuck in the head. Any ideas for getting it out?

We need a Tech section on the forum!
Rob

Can you get all the bolts off to remove the manifold. If so, heat the stud with a torch and use a stud puller. Get one at your local Craftsman tool dealer. Should not be too big a problem as long as you can get the manifold off and out of the way.

I guess what I was trying to say, is that the extractor is broken off inside the stud, which is broken off inside the head....flush, I might add....
Rob

OK. that makes a big diff right there. What size is that stud? I can't remember right off hand. You might be able to get a carbide tipped end mill bit small enough to chuck in a drill and get it out that way, but if you can't get the right size, you'll be looking at drilling and tapping the head for a larger bolt. You might have to take this one to a machine shop to get it fixed since that e z out in broken off in there.

It's a 3/8" stud, grade 5...but that damn extractor is hardened! Some say I can heat it to ruin the temper, then chip it out with a small punch....
Rob

That might work, have not tried it. I'd check with a machine shop or some place like Granger that sells to companies and the like. If they have a end mill bit small enough with a carbide tip, it will cut right through it with no problems at all.

dwc43 wrote:That might work, have not tried it. I'd check with a machine shop or some place like Granger that sells to companies and the like. If they have a end mill bit small enough with a carbide tip, it will cut right through it with no problems at all.

I'll look for one this week, and give it a shot!
Rob

If you don't find one let me know. I have a book you can order them from. I'll have to find it and see what sizes they have.

Thanks, man...we've got an industrial supply place here that I'm gonna try tonight...I'll let you know!
Rob

Did you find a end mill bit yet? Check www.use-enco.com They have several styles and types listed. There's some two and 4 flutes starting at $4.99 ea. Sizes start at 1/32 6/64 1/16 3/32 1/8 5/32 3/16 7/32 1/4 5/16 3/8 7/16 1/2 5/8 3/4. As long as you don't get one bigger than a 1/2" it will fit in a 1/2" drill chuck and you should be able to drill it out.

my locals did not have those end mill bits...looks like I'll be picking some of those up via the Net!
Rob

Before you go after what's left of the Stud, it might be well worth your while to send me the head. I've a machine shop (chuzz knows me) and let me get out before you have a drill go off on some tangent...
Bill

Hey Rob. Did you get the extractor out and the stud too? Just wondering. Need an update ... lol.

Ghost, I wish you luck but this has disaster written all over it... been here, done this... found it better to clamp it on the table of my mill and do it right the rist time... after years of rust, heat and corrosion, .... nature usually wins

Been busy with extra-curricular activities lately, and haven't had time to work on it...I'll update as soon as I do!
Rob