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[kingplym]

ah where once i was blind now i can see! i use the mig welder to weld the miggy

[Bent valve]

 A trick I have used in the past on snapped banjo bolts on hydraulic systems, is to find an allen key which is slightly larger across the diagonal of the hexagon than the inside diameter of the snapped bolt and tap it in with a hammer.
 You can then try to work it backwards and forwards gently after applying some good penetrating oil.

 You may be able to get a replacement bolt tomorrow from a hydraulic hose specialist, I THINK it is a 3/8 BSP Banjo bolt, although it could be a metric equivalent.  take your other one along to match it up.

[kingplym]

thanx bentvalve i just might give that a go

[kingplym]

ok leaving it too soak in wd to try n loosen it hasnt worked.

i banged a 10mm allen key down the centre or the bolt and promptley broke a 11mm socket trying to turn the allen key.

i am unable to fit a standard size hacksaw blade down the centre of the bolt and trying to use a junior blade is a joke, and as stated in previous post again i am losing my sense of humour with this!!!

please someone help

[M0T0RVATE]

Anyone got any idea if a nut splitter will help...
Possibly will help get the bit out by splitting and distorting it...
Then use pliers to pull/twist it out...

 :question

[Lizzie_Zoom]

I have been following this thread with interest, seeing what others have recommended.

However, one thing that no one has yet mentioned is a trick I have unfortunately had to use in the past.  That is cut the stud / bolt flush and drill it out using a bit that is smaller than the diameter of the stud, and maybe drilling pilot holes in sequence. Takes some effort and patience, yes, but does, if careful, extracts the bolt cleanly.  

It may of course be necessary to re-tap the hole.

Just an idea amongst many it seems, and assuming there is not enough room for a stud extractor to be used.!

[Marks DTM Calib]

Stud extractor is not a good idea (coz there shite, hard and seem to always snap!), the allen key method is a little iffy as the hollow bolt walls are thin and both these methods will force the walls of the bolt tighter against the head.

As said, its a saw job.....

[Lizzie_Zoom]

Stud extractor is not a good idea (coz there shite, hard and seem to always snap!), the allen key method is a little iffy as the hollow bolt walls are thin and both these methods will force the walls of the bolt tighter against the head.

As said, its a saw job.....

But Mark is there any problem in drilling out as I suggest, and as I have had to do in the past?

[Andy B]

I think we're all at crossed purposes here.
What I believe kingplym has sheared is something similar to this .....

ie the hollow bolt that bolts down the 'banjo' end of the coolant hose. i could of course be wrong  .... again.

[Lizzie_Zoom]

I think we're all at crossed purposes here.
What I believe kingplym has sheared is something similar to this .....

ie the hollow bolt that bolts down the 'banjo' end of the coolant hose. i could of course be wrong  .... again.

If that is the case, drilling out would be even easier to do than on a solid bolt.

[kingplym]

that is the type of bolt but mine has 4 holes at the top of the neck. i think im just gona have to keep trying with the junior blade, with which i cannot get any purchase and feels like im pissing against the preverbial wind :-/

[Andy B]

that is the type of bolt but mine has 4 holes at the top of the neck. i think im just gona have to keep trying with the junior blade, with which i cannot get any purchase and feels like im pissing against the preverbial wind :-/

How about a 3 square (triangular profile) file? Might take a little longer but will be a bit easier to use.

[sassanach]

you really need to beg,borrow or befriend somebody with a mig plant mate!!

[kingplym]

i have managed to make one cut from the inside of the bolt to the thread. still no joy. but i stopped as i reached the thread, or do i carry on. i started to make a second cut but all the little muscles in me little hand are hurting.

still im  slowley getting me humour back

[mantahatch]

I think we're all at crossed purposes here.
What I believe kingplym has sheared is something similar to this .....

ie the hollow bolt that bolts down the 'banjo' end of the coolant hose. i could of course be wrong  .... again.

If that is the case, drilling out would be even easier to do than on a solid bolt.

I totally agree with you Lizzie, if it is hollow then it could not be easier to drill out. The only thing I would add is drill slightly under size and the knock out the remaing bit with drift, and have a vacuum cleaner held very close to the bit when drilling to collect as much swark as possible.

HTH

Mike