Originally Posted by rlw7353
Well thanks, thats explaining why these things dont seem to want to come out easy. I dont weld but I saw that process online. Is this a common enough practice that I could I get someone to come out and do that? I ordered some backouts that are a little different from what I've seen before. these have a relatively short reverse thread grabber section that doesn't go down to a point and a hex head on top. It looked to me like it would have less of a possibility of breaking off.
Another question, when I get the 80mm broken stud out and try to put the 90mm bolt in, is the hole tapped all the way down or do I have to add some threads? thanks
Everything Squire said was right on the money. If you know anyone that is even a semi skilled welder he should be able to do the job. If you do not know a welder and if there is a machine or fab shop close by you could discreetly ask if any of the guys has a small welder and if for a small fee they would remove the bolts, often this works because many machinist and welders moonlight.
My next suggestion could be more expensive, if you live near a good sized city, there may be a mobile service that specializes in removing broken taps, drills bolts spark plugs or whatever. Usually they are machinist that went in on their own or they are moonlighting. They get really skilled at removing broken taps drill and bolts because they do it so often in day in and day out work. One guy I know built his own EDM and was making a few extra buck under the table with it. The link below is an example of what to look for.
SO....Search your local yellow pages for broken tap or broken bolt removal service. They should have all the required tools they may even have an EDM machine, although EDM is messy and works better on broken taps and drills than on bolts.
Say...Just so you have the numbers...The original OEM flange bolts with just the ball joint screwed in to a depth of 1.200"
90 mm bolts with flat washer and 2" spacer and the ball joint will screw in to a depth of 1.249" = .049" deeper that is less than one thread deeper so as Squire said thread depth will not be a problem.