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post #12 of Old 10-03-2012
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Re: Advice on removing snapped s/s bolts from alu block

Couple of things you want to do.
First heat it very slowly w/ a propane torch. Do NOT use a MAPP torch (too hot) Don't get it so hot it turns color, just heat it up.
Take a ball peen hammer and tap gently all around the broken off piece. Spray some PB blaster or other type "stuff" on it. Tap some more.
Let it cool a bit and then try using a LEFT hand twist drill bit. You'll need a cobalt bit to drill into the SS. Start w/ a smallish bit and after you get some depth, go back and use a slightly bigger bit. If you're lucky the drill bit will grab and twist it out. More than not however, you'll have to drill enough to get an easy out in.
Keep heating and cooling. The difference in the metals may eventually let it break free.

Nothing wrong w/ using SS and AL. Just need to make certain you smear some TEFGEL on the fastener to isolate the metals from each other.

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