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Old 08-26-2017, 10:38 PM   #1
81turbota
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Alternator bolt broken off in head

Well guys, this happened. I blame the cheap chrome alternator bracket on putting too much downwards pressure on the alternator.

Anyways, it's broken off well below the surface. I would normally weld a nut onto it but it's sunk in 1/8-3/16". I have had terrible luck with easy outs, do you all have any other ideas?

Thanks!
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Old 08-26-2017, 11:02 PM   #2
Captainfab
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Re: Alternator bolt broken off in head

If you have a wirefeed, I would build up the end of the bolt using multiple 'tacks' until you build it up enough to be able to weld a nut onto it. Otherwise, you will likely just have to drill it out. Start with say a 3/16" bit and work your way up until all you have left is the threads and then pick them out and run a tap in the hole. I know easier said than done.
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Old 08-26-2017, 11:13 PM   #3
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Re: Alternator bolt broken off in head

drill and ease out...I know...it sucks....
if you try to drill the bolt out make sure your centered and straight on the broke bolt or your likely to cause more damage
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Old 08-26-2017, 11:32 PM   #4
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Re: Alternator bolt broken off in head

I'm with CaptainFab. When I have a bolt broken off below the surface I'll drill out a nut of the same diameter as the bolt to about a 16th of an inch from the other side and hold it against the surface as a guide for my wife feed. It lets me build up the weld on the bolt without having to worry so much about hitting the sides of the opening.

Looking at your pic I'm pretty confident that it would work for you.
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Old 08-26-2017, 11:38 PM   #5
81turbota
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Re: Alternator bolt broken off in head

Thanks gentlemen! I have a MIG and will try it tomorrow.
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Old 08-26-2017, 11:55 PM   #6
BossHogg69
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Re: Alternator bolt broken off in head

Left hand drill bits almost always work, but if it won't come out with that, I like Irwin bolt extractors. You'll already have a hole to work with. I'm not a fan of regular ez outs.
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Old 08-27-2017, 05:05 PM   #7
68gmsee
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Re: Alternator bolt broken off in head

The good thing about this broken bolt is that it broke due to either defective bolt or vibration or both. It wasn't because it was frozen in place so it should come out fairly easy with above suggestions. Heat and a little penetrating oil like Blaster or Liquid Wrench will help also.
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Old 09-03-2017, 04:59 PM   #8
81turbota
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Re: Alternator bolt broken off in head

Success.

I delayed since I was waiting to borrow the angle drill from a coworker. It saved me from having to remove the radiator shroud.

Spun right out after I drilled a 3/16" hole through it.

Thanks everyone!

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Old 09-03-2017, 07:38 PM   #9
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Re: Alternator bolt broken off in head

Great, I love a story with a happy ending!!!
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Old 09-03-2017, 09:37 PM   #10
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Re: Alternator bolt broken off in head

Thanks for coming back and letting us know how it turned out.
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