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Location: Callao, VA
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Re: Advice on removing snapped s/s bolts from alu block
your best bet would be to try easy outs, then drilling if that fails....worse case is dremeling them out completely
either way you are likely going to have to retap, If that is possible - I would look at using studs - you may have to use a larger section in the AL that switches to M6 through the housing, else drill it out if you can.
stainless and AL can be problematic, as you are seeing, in a marine environment with out insulating or large mass....and especially crevice corrosion as you are up against....
not sure I would replace them with stainless, I would do a bit more research on, else make sure your fasteners are top quality..then there is the fact that stainless really can't stretch in AL like you would want a bolt to do, and you need the correct anti-seize if you ever want to take them out without destroying the AL threads....
more to this than you would think....Yamaha should know better
Last edited by kd3pc; 10-03-2012 at 12:59 PM.