04-24-2020, 12:23 PM | #1 |
Join Date: Mar 2010
Location: Volcano, Ca
Posts: 7,112
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Snapped Rear Rack Bolt
Ok gang, my neighbor, who I sold the white RX3 to, decided he wanted to paint the rear grab bar/trunk mount. In the process, he snapped the long center mounting bolt.
I know, I know....how?...you may ask. Let me just say he's a great guy, an awesome father, well-meaning, is a great cook, and has a huge heart....but has a tendency to be "a bull in the china shop of life". I think the only pair of bars he hasn't gone over is a rototiller....but give him time. You get the idea. That said, has anyone else done this? There is nothing sticking out. It's actually recessed. He wants me to drill it and use an easy-out but my record with this process is lackluster, at best. If I'm lucky enough to drill a perfect hole (without hitting the threads) in a hardened bolt, the easy-out usually snaps, compounding the problem. Anyone else done this? Can it be drilled completely through and nut and bolted? I guess I'll have to completely disassemble the rear and see where that hole goes to. Any RX3 expertise is greatly appreciated.
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"Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350 |
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04-24-2020, 04:13 PM | #3 |
Join Date: Mar 2010
Location: Volcano, Ca
Posts: 7,112
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Yes, and I like this idea much better!
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"Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350 |
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04-24-2020, 08:18 PM | #4 |
Join Date: Aug 2016
Posts: 365
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Sounds Like A Job For TIG Welding
If the bolt is recessed like you say, you probably won't be able to get any fusion with stick or MIG welding a nut. It might be necessary to use TIG welding to build up the end of the broken bolt until it is proud of the surface, then weld a nut onto that built up section or just grab it with a pair of locking pliers. With TIG welding, you'll be able to very precisely control the arc and where you deposit filler metal, so you'll be less likely to mar the rack or weld the nut to it.
I went through this on a Dodge caravan that some previous mechanic attempted to replace the water pump on, but snapped off one of the 6mm x 20mm bolts. It was sitting below the suface of the aluminum timing cover/water pump housing and I had to build it up with my TIG welder, in order to grasp it with a pair of ViseGrips and thread it out. This took four or five attempts before I got good fusion with the bolt, so don't get discouraged if it doesn't work the first couple of tries. |
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04-25-2020, 12:12 PM | #5 |
Join Date: Sep 2018
Location: Peoria, AZ
Posts: 334
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Hardened? Most of the stuff on this bike is Chinesium and soft.
Start with a center punch, and dimple the heck out of the bolt. So you guarantee the drill bit won't walk. Then drill with a small bit. Follow up with the right bit for the extractor. Use cutting lube during this process, I very highly recommend Tap Magic. It really is magic.
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2016 RX3 2002 Honda CBR1100XX |
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04-26-2020, 01:24 PM | #6 | |
Join Date: Mar 2010
Location: Volcano, Ca
Posts: 7,112
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Quote:
Update: Well, I finally got a chance to check it out. The neighbor started drilling a hole....and proceeded to spin it down to bottom. Let the fun begin.....
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"Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350 |
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04-26-2020, 01:37 PM | #7 |
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Join Date: Oct 2016
Location: Houma, La.
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That's where a left hand drill bit comes in handy.
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04-27-2020, 08:57 PM | #9 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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Exactly what I was thinking.
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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04-28-2020, 04:43 PM | #10 |
Join Date: Mar 2010
Location: Volcano, Ca
Posts: 7,112
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Of course. the one set of drill bits I don't have.....
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"Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350 |
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04-29-2020, 12:56 AM | #12 |
Join Date: Mar 2010
Location: Volcano, Ca
Posts: 7,112
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I shall give that a shot! if he wasn't one of my dearest friends.....etc....etc..... you know....
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"Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350 |
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