Help - Bolt Sheared Off - YZF426

In article <1109001375.088468.176460 RemoveThis @z14g2000cwz.googlegroups.com>,
Jerry Puckett <puckett4704 RemoveThis @sbcglobal.net> wrote:
 >My first post using Google so apologies in advance for anything stupid.
 >
 >Sub frame on 2000 YZF426 has a bolt that sheared off. Steel bolt in
 >aluminum threads. Haven't seen it - Brandon just called and told me
 >about it. Sounds like a bolt about 3" long at the upper front
 >attachment point. Twisted off a ez-out trying to fix it.

Oops.

Can you weld another bolt to the stub of the broken one?
Then use that to turn it.

I've been able to use a dremel and carbide cutter to grind out the
remnants of a broken ez-out. It took a long time though.
Anything less than carbide won't work; the ez-out is very hard.


Eric<!-- ~MESSAGE_AFTER~ -->
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"Jerry Puckett" <puckett4704.RemoveThis@sbcglobal.net> wrote in message
news:1109001375.088468.176460@z14g2000cwz.googlegroups.com...
 > My first post using Google so apologies in advance for anything stupid.
 >
 > Sub frame on 2000 YZF426 has a bolt that sheared off. Steel bolt in
 > aluminum threads. Haven't seen it - Brandon just called and told me
 > about it. Sounds like a bolt about 3" long at the upper front
 > attachment point. Twisted off a ez-out trying to fix it.
 >
 > Found another sub frame on E-bay but don't think we can get it here in
 > time to leave for WUDI on Thursday!!
 >
 > Any ideas?
 >
 > Thanks,
 >

You need a machine shop with an ELOX machine. It will burn through the
easyout you have broken in the hole. If it's in the mainframe you need a
shop with a portable one. It would have been easy until the broken easyout
problem.

Noob<!-- ~MESSAGE_AFTER~ -->
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"Jerry Puckett" <puckett4704 RemoveThis @sbcglobal.net> wrote in message
news:1109001375.088468.176460@z14g2000cwz.googlegroups.com...
 > My first post using Google so apologies in advance for anything stupid.
 >
 > Sub frame on 2000 YZF426 has a bolt that sheared off. Steel bolt in
 > aluminum threads. Haven't seen it - Brandon just called and told me
 > about it. Sounds like a bolt about 3" long at the upper front
 > attachment point. Twisted off a ez-out trying to fix it.
 >
 > Found another sub frame on E-bay but don't think we can get it here in
 > time to leave for WUDI on Thursday!!
 >
 > Any ideas?
 >
 > Thanks,

Drill the stuck bolt remnant from the other side (I assume a subframe bolt
wouldn't be into a blind hole). If you do it carefully and get a little
lucky, you'll run into the end of the broken EZ Out. If you do, and if you
need the extra depth for your newly drilled hole, try sticking a drift in
there and punching the EZ Out out. If you can get another EZ Out to bite in
the newly drilled hole without messing with the broken one, leave it there.
Get the new EZ Out seated in the bolt from one side or the other, then heat
the aluminum threaded bit with a propane torch. Don't go nuts, but get it a
little too hot to touch, then try unscrewing it. You can easily heat it up
to 300 F without worrying about any effect on the aluminum as long as you
don't keep it that hot for a long time (hours). Since the aluminum expands
more than the steel, heat should loosen the grip on the bolt.
Unless you can't drill the bolt from the backside. Then, that broken EZ Out
pretty well screws you unless you have access to a good machine shop with an
EDM (Electrostatic Discharge Machining) machine, which burns it out with
precision sparks, similar to the ELOX machine Noob mentioned I assume.
Good luck, guys.

Tim H<!-- ~MESSAGE_AFTER~ -->
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"Craig Faison" <cfaison.RemoveThis@magpage.com> wrote >
 > looking like I won't make WUDI...
Crap - that sucks.
Forecast 50's during the day and high 30's at night with no rain. Looks like
perfect weather so far.<!-- ~MESSAGE_AFTER~ -->
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"Tim Harrell" <tntharrell.DeleteThis@somethingorother.com> wrote

 >Unless you can't drill the bolt from the backside.

Yup! It's a twin frame at that point (picture a swingarm) so we would need a
bit about 8" long to go all the way through.

 >Then, that broken EZ Out pretty well screws you

Yup!

 >unless you have access to a good machine shop with an EDM

Working that today. The high school has a very good machine shop and he went
through the program so we're going to see if they'll let him come back in
and fix it. Said he knows they have the EDM machine and/or a mill that would
work. Sandy works for the school district so she's trying to pull some
strings!<!-- ~MESSAGE_AFTER~ -->
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"Kim Neubert" <noob.TakeThisOut@raex.com> wrote
 >
 > You need a machine shop with an ELOX machine. It will burn through the
 > easyout you have broken in the hole.

As long as I'm learning, tell me about ELOX. I think I understand EDM but
hadn't heard about ELOX.<!-- ~MESSAGE_AFTER~ -->
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elox is a brand name machine that has an electrode with typically either
copper or carbon tip that are precisely placed on the part you want zapped
by a cnc style axis machine they usually take up about a 10foot square and
some of the edm machines are smaller footprint thus more desirable... you
issue would be to be able to place the part in the machine..... it's hard to
pick up a whole bike and lay it on a bed (unless it's a big bed)


"Jerry Puckett" <puckett4704.RemoveThis@deletethissbcglobal.net> wrote in message
news:YUESd.39900$wi2.21010@newssvr11.news.prodigy.com...
 > "Kim Neubert" <noob.RemoveThis@raex.com> wrote
  >>
  >> You need a machine shop with an ELOX machine. It will burn through the
  >> easyout you have broken in the hole.
 >
 > As long as I'm learning, tell me about ELOX. I think I understand EDM but
 > hadn't heard about ELOX.
 >
 ><!-- ~MESSAGE_AFTER~ -->
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On Tue, 22 Feb 2005, Jerry Puckett wrote:
 > Crap - that sucks.
 > Forecast 50's during the day and high 30's at night with no rain. Looks like
 > perfect weather so far.

Yeah... bummed, but it's just not in the cards. Have fun and take lots of
pictures!

Craig<!-- ~MESSAGE_AFTER~ -->
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"Jerry Puckett" <puckett4704.DeleteThis@deletethissbcglobal.net> wrote in message
news:YUESd.39900$wi2.21010@newssvr11.news.prodigy.com...
 > "Kim Neubert" <noob.DeleteThis@raex.com> wrote
  > >
  > > You need a machine shop with an ELOX machine. It will burn through the
  > > easyout you have broken in the hole.
 >
 > As long as I'm learning, tell me about ELOX. I think I understand EDM but
 > hadn't heard about ELOX.
 >
 >

Case of using brand names. Elox makes EDM machines. Sorry about that.

Noob<!-- ~MESSAGE_AFTER~ -->
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