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fred cook fred cook is offline
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Join Date: May 2001
Location: Deep South
Posts: 4,722
Garage
Cool Drilling out broken bolt....

Take a piece of stiff paper and make a template of the four holes that the mount bolts to. Transfer the template onto a 1/2" (or thicker) piece of steel. Using a drill press, drill out the holes as accurately as possible. Then bolt this drill guide to the end of the engine using the 3 good bolt holes. If you have done this correctly, you will be able to drill the offending bolt out and stay centered. You should be able to get a small piece of steel from a machine shop for just a few dollars, and maybe even get them to do the drilling. The hole where the broken bolt is located can be drilled partially thru the steel plate, with a smaller pilot hole going all the way thru. That way you can start with a small bit and keep getting larger as necessary. This will not only center the drilled hole, but should keep the bit vertical to the hole. I just went thru this process for some broken exhaust studs and it worked well.

Good Luck!

Fred Cook
'80 911SC coupe
Old 01-03-2004, 05:22 PM
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