Snapped bolt on frame cross member, any creative solutions?

I think he was meaning on the back side of the bolt and just go all the way through with it. Could work if it didn't drag damaged volt threads through.

 

I think he's talking about the OD of the threads where the head snapped off. A drill guide is great and accurate, but I don't see it making much sense here.

 

Thanks all, for the the suggestions. I'll give some of this a try and hopefully get it out of there!

 

edit left handed drill bit with an old 90 degree adapter. No drill bushing just good auto center punch placement and a little luck.

 

Could be. My profession for the last 25+ years as a machinist, I've seen all kinds of ways to do repairs. The guys most allways bring it to me after it's even been boogered up worse and most times I find a way. There's been lots of good tips given.

 

Drill guides are sweet, but without a one off custom one, upside down on truck, it's hard.

 

Another option possibly; if where the bolt head is broken off, if it is broken off cleanly, then some heat, penetrating fluid and vice grips to thread it out from the top side. Would be my last choice, but sometimes tools and skill levels are limited.

 

Yep this is the method I'm using on the sway bar bracket bolts I snapped on my 4runner.

Sometimes skipping ahead to drilling and tapping is the way to go. Mine snapped on removal, which is pretty common for a 13 year old vehicle in Upstate NY.

 

You can order custom ones online for around 10-20 bucks or visit a local machine shop, it may seem rediculous for one bolt but it depends on if you want to mess it up to the point you're cutting the existing nut off the frame and welding on a replacement. I've removed probably thousands of bolts using this method but my employer literally has sets of drill bushings with welded on handles that fit perfectly over fastener heads/collars.

A drill guide to center a pilot hole for extractor bit is always a great idea since it'll ensure the extractor bit is exactly in line with the broken off bolt. If it's off slightly it's easy to snap the bit.

If there's enough room for access you can just drill it by hand, but without experience it's not exactly easy to get it strait . Worst case the bolt won't come out and you'll have just the nut to cut off which will be much easier without the bolt stuck in it. I'd use one of those vibrating dremel tools because the blade will bend and slide along the frame cutting the bolt flush.