It all started when ……

[K_Wiz]

I wanted to fix the weeping coolant on the outlet. The generator bracket… I thought I was moving the bolt back an forth to loosen it up and then snap

. I am looking for advice on the best way to drill it out and retap. In the meantime I used my belt sander and slowly took metal off till the sealing area was flat again.

. I also went to my local Auto Zone and found a felpro gasket that would work for around 4 bucks. I will include a part number and a picture when I get home after work.

[BullDAWG]

Is that a blind hole or does it go all the way through?

Broken bolt looks to be higher than the part it broke off in. I'd try using a chisel and hammer it counter clockwise after soaking it in liquid wrench or pb blaster. If that doesn't work then file broken bolt flat, use a center punch to make a dimple in the center. Using the largest bolt extractor I could on it. Use the correct left handed drill bit for the size extractor you're using.

[Ihandy]

I'd try welding a nut to it the heat will help loosen it up a bit

[Cubfriend]

Or you could save a little frustration and but another water neck. They are not too expensive.

[inairam]

Ohio State football coach Woddie Hayes was often quoted as saying "only three things can happen when you pass and two of them are bad."

That is how a feel sometimes when I have an idea to fix something small on a cub. A good thing can come out of it but a couple a bad things can come out as well.

[tmays]

Straightforward fix. You’ve already started off correctly grinding it flat. Center punch it and drill it out with left hand drill bits preferably. If you don’t have those, not a problem. I’ve found that most broken bolts don’t loosen as you drill them with left hand bits. Start small and go up to the drill size recommended for that size bolt. Run a tap in, clean hole out and you’re done.

[Barnyard]

You’ve already started off correctly grinding it flat.

I don't see where he said that.

[Bob McCarty]

Before drilling, I'd cut a slot in it for a screwdriver, heat it red hot with a torch and see if it will back out.

[tmays]

You’ve already started off correctly grinding it flat.

I don't see where he said that.

You are correct. I should’ve read with better comprehension. He ground the gasket surface flat.

[ntrenn]

I’ve found the mapp gas torch to be a welcome companion on journeys of this type. It will heat the bolt hot enough to soften it and it will drill easier.

[NJ Farmer]

Make sure you use GOOD HSS drill bits and drill them slowly starting with a 1/16 or 5/32 drill and step up in size slowing.

NJ Farmer

[ajhbike]

I just had to remove 4 broken lug bolts off a JD B and I tried the extractors and broke 2 off in the holes I had drilled out. Thank goodness I had drilled the holes through the bolt and could punch the broken extractors out. I ended up progressively drilling out the lugs. I'll never use another extractor. If I were in this situation I would drill it out.

[Barnyard]

Extractors are about the worst thing you can use.

[Mht]

Snap on tools used to sell a set of extractors that were straight, not tapered. They had flutes or ridges on the sides and a nut like piece that slid over and engaged the flutes and allowed them to be turned with a wrench. I have a set that I purchased when working as a heavy equipment mechanic. They were pretty effective. I agree that the square tapered and spiral style extractors are useless

[SamsFarm]

Snap on tools used to sell a set of extractors that were straight, not tapered. They had flutes or ridges on the sides and a nut like piece that slid over and engaged the flutes and allowed them to be turned with a wrench. I have a set that I purchased when working as a heavy equipment mechanic. They were pretty effective. I agree that the square tapered and spiral style extractors are useless

Ridgid made those for snap on.....
https://www.ridgid.com/us/en/25-screw-extractor-set

I picked up one at a auction years back for around 30 bucks it seems.