[enkeivette]

Broke off the water pump bolt, drilled a hole through the bolt perfectly, all the way through, spun in the easy-out, began to twist... and snap.

Now I'm trying to drill the easy-out, out, and it's not easy. About a 1/16" deep, drill bit is dull already... using wd40.

What do I do now?!

[Vettezuki]

Originally Posted by enkeivette

Broke off the water pump bolt, drilled a hole through the bolt perfectly, all the way through, spun in the easy-out, began to twist... and snap.

Now I'm trying to drill the easy-out, out, and it's not easy. About a 1/16" deep, drill bit is dull already... using wd40.

What do I do now?!

Was your easy out forged or cast? If it was forged you're probably going to need a tungsten carbide or polycrystalline diamond bit.

[big_G]

About all I know how to do is to get a real sharp tapered round punch and shatter the easy-out. They are brittle steel. Hit it as many times as needed to break it. Vacuum out the chips as you go. You may be able then to punch any fragments clean through the pre-drilled hole. Check with a local Snap-On tool jobber (or similar) and see if they have reverse drill bits. The heat from drilling sometimes will release the broken part.

[enkeivette]

In SD, didn't have a hammer or a punch. I used a dremel with a carbide bit to cut the bolt out, the filled it with JB weld to repair the threads. Drilled and retapped. Installed the bolt with silicone. Seals fine.

[Vettezuki]

Originally Posted by enkeivette

In SD, didn't have a hammer or a punch. I used a dremel with a carbide bit to cut the bolt out, the filled it with JB weld to repair the threads. Drilled and retapped. Installed the bolt with silicone. Seals fine.

I wonder how well the JB weld bond will hold up over time.

[enkeivette]

Since there is a thick metal plate completely covering the repair, held in by another bolt 1 1/2 inches away with perfect threads, I'm sure it will be fine.

BUT, when I bring the boat back up to OC, I plan to grind it off, weld it closed and redrill/ tap.