Join Date: Oct 2012
Location: Nashville TN
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Re: Advice on removing snapped s/s bolts from alu block
Easy outs are almost useless in most cases. If the easy out snaps you are going to have a much harder time with any other method since easy outs are so hard.
Best way that works for me is using a tig welder to build the broken bolt up high enough to then weld a nut of the same metal type to it. This works about 90% of the time when a bolt that is broken is a different metal that the surrounding metal.
Also as was already mentioned take in to a shop with a drill press to make sure the bit goes in straight and then use a helicoil.