caterhamnut Posted February 9, 2003 Share Posted February 9, 2003 40 miles into a 150 mile trip down to Somerset this evening my rear exhaust mounting broke. Strapped it up for the rest of the journey with no problems. The metal strap between the car body and the end of the exhaust has snapped, around the bolt. Despite lots or release spray etc, the bolt head has snapped off whilst trying to take it out of the chassis rail. I thought this might happen, as the front one (unused in this installation) has already sheared off. Whats the best way to fix it? I thinking drill it out, slightly smaller diameter, tapp the hole and use a very slightly thinner bolt into the chassis? Any ideas? ta 😬32,000 miles in 15 months! angus@tinyworld.co.uk Caterham pics here Link to comment Share on other sites More sharing options...
mav Posted February 9, 2003 Share Posted February 9, 2003 If there is any of the bolt protruding, then use on of those stud removal tools - available in Halfords. That should enable you to remove the bolt completely and then use a new one in its place. Link to comment Share on other sites More sharing options...
TomBerlin Posted February 9, 2003 Share Posted February 9, 2003 If the bolt broke while trying to remove it, then it is most likely seized. This being the case an easy out will not work unless the bolt was weakened by vibration. Easyouts really only work if the threads are in good shape. Best solution is to try to drill dead center on the broken piece and rethread to original size or drill slightly larger and either use a larger bolt or helicoil. Good luck. Link to comment Share on other sites More sharing options...
CHRIS CLARK Posted February 9, 2003 Share Posted February 9, 2003 Tom. I'd agree with you. Worst of all scenarios is breaking the 'Easi-Out' in the bolt stub. Chance of removal then is just about nil! Go the 'drill out & re-tap' option. Clamshell Club Founder Member. Link to comment Share on other sites More sharing options...
AMMO Posted February 9, 2003 Share Posted February 9, 2003 Don't use a removal tool. If that shears off (which it probably will) the only way to get it out is by spark eroding. Drill it out and re-tap or helicoil as Tom suggests. AMMO Link to comment Share on other sites More sharing options...
TomBerlin Posted February 9, 2003 Share Posted February 9, 2003 I haven't been at this very long but isn't 3 replies in total agreement close to some sort of record? Link to comment Share on other sites More sharing options...
Mr Locust Posted February 9, 2003 Share Posted February 9, 2003 Another agree Drill progressively larger on centre until you can 'pick' the threads of the bolt out of the hole. Then clean up with a tap. 😬 Link to comment Share on other sites More sharing options...
TomBerlin Posted February 9, 2003 Share Posted February 9, 2003 Yes to Mr Locust. I've had success with that routine many times also. Link to comment Share on other sites More sharing options...
caterhamnut Posted February 9, 2003 Author Share Posted February 9, 2003 mmm - I agree as well then!! Drill out carefully with progressively larger drills then clean with tap sounds a good plan. Thanks all! 😬32,000 miles in 15 months! angus@tinyworld.co.uk Caterham pics here Link to comment Share on other sites More sharing options...
Mr Locust Posted February 10, 2003 Share Posted February 10, 2003 A&T Take it easy. The more steps / finer graduations in drill size you can use the easier it should be and the less chance of breaking a drill off in the hole. Best of British 😬 Link to comment Share on other sites More sharing options...
AMMO Posted February 10, 2003 Share Posted February 10, 2003 The trick is to get the first hole really central and in line. Get someone to help you line the drill up. If you look from above you can see if it's lined up correctly. Someone else needs to watch from the side. Dot punch and use a sharp 3 mm drill to start with. Good luck. AMMO Link to comment Share on other sites More sharing options...
caterhamnut Posted February 10, 2003 Author Share Posted February 10, 2003 thanks for advice - incidently, what size is the thread when I eventually get to it? 😬32,000 miles in 15 months! angus@tinyworld.co.uk Caterham pics here Link to comment Share on other sites More sharing options...
Mr Locust Posted February 10, 2003 Share Posted February 10, 2003 I just looked at mine (which hasn't been fitted yet). Appears to be 5/16" unf on my car and bolts supplied are 5/16" unf / 3/4" long with 1/2" A/F Hex Head (assuming I've pulled the right ones out of the miscellaneous 'everything else' fasteners pack). Hope this helps 😬 Link to comment Share on other sites More sharing options...
allen Posted February 10, 2003 Share Posted February 10, 2003 Angus, I'm in Minehead, with drill, taps and dies, working nights at the moment, so available tomorow afternoon (Tues 11th) if you need a hand. 01643 703571 after about 1.30 if you need me. allen Link to comment Share on other sites More sharing options...
DaveMorris Posted February 10, 2003 Share Posted February 10, 2003 Last / another bit of advice - to more easily see where to need to mark the hole centre use angle grinder or file to get the fave of the sheared bolt flush with the parent metal. (If grinder used then protect rest of car + eyes + wife from flying sparks which get everywhere and really b***** up the paint job) You SHOULD be able to see a perfect, slightly darker, hairline circle which is the interface between bolt thread and the hole. Now all you have to do get the punch in right place (the middle of the hole) and manage to hit it. the rest is, as they say, a piece of cake. Dave. Link to comment Share on other sites More sharing options...
caterhamnut Posted February 11, 2003 Author Share Posted February 11, 2003 thanks for the tips guys - will do the job at work today. Allen, thanks for the offer, unfortunatly I am back in london ☹️ which is a shame as the Taunton to Minehead road is a blast if empty! Thanks anyway. 😬32,000 miles in 15 months! angus@tinyworld.co.uk Caterham pics here Link to comment Share on other sites More sharing options...
YW Sin Posted February 11, 2003 Share Posted February 11, 2003 Why do we all find so many seazed nuts and bolts on the 7 Chassis??? Caterham should really look into this issue. I am getting sick and tired of dealing with bolts that won't come out even on my 7 year old chassis which is in good shape! A ll standard, Classic 1.7 X-flow Edited by - yw sin on 11 Feb 2003 13:39:51 Link to comment Share on other sites More sharing options...
caterhamnut Posted February 11, 2003 Author Share Posted February 11, 2003 all sorted - ta for advice! Y W Sin - belated thanks for your email a while ago, and did you know there is a 'test session' day at Crois en Ternoise this Sunday 16th - we will be there - can't be a million miles from you near Paris? 😬32,000 miles in 15 months! angus@tinyworld.co.uk Caterham pics here Link to comment Share on other sites More sharing options...
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