How to remove a broken bolt or stud with an easy out

If you've broken off a bolt or stud, you no doubt think the end has arrived - not necessarily!! There are several ways to get that troublesome piece of metal out - even if it broke off flush with the surface, and the aftermarket has several different tools available. First on the list would be an Easy out, which comes in a set of several different sizes. Instead of using a standard drill bit to drill a hole in your workpiece, buy a set of left handed drill bits and chuck up the appropriate size in a reversible, variable speed drill. Use a fine point metal punch to make a dimple in the CENTER of the bolt or stud. The closer to center you are the greater the chance for success. Set the drill at a slow speed. It would be best to have the piece horizontal so you can use cutting oil ( or motor oil in a pinch) to help lubricate the hole as you drill. In either case, drill slowly into the bolt, making sure you are level and straight.You can guide the bit by maneuvering the drill at different angles to keep your hole centered. Drill at least 3/4 inch into the bolt, using plenty of oil and making sure you don't overheat the bit - you don't want it to break off. Watch closely as you drill - it is possible that the bolt could back out of the hole as you go! When you've reached the desired depth, remove the bit and, for added help, use an oxygen acetylene torch to heat up the bolt. stop just before it begins to glow orange and quickly push a plain paraffin candle into the side of the bolt.( If you don't have access to a torch, you can try a rust buster or other penetrating oil to release the threads from the hole cavity.) Now lightly tap your easy out into the bolt with a hammer and carefully turn it with an open end or crescent wrench. You'll need to work quickly before the bolt cools too much. The wax will work its way in between the threads of the bolt by capillary action, releasing the bolt for an easier removal. If this doesn't work, then you'll probably need to drill out the bolt fragments and use an appropriately sized Helicoil kit to replace the threads. Before you re - install a new bolt or stud, get the right size and pitch of a thread tap and tap out ( or re cut ) the threads to make sure your new fastener will not strip out the old threads.
Best of luck!!