Fill the hole with lubricant, and drill all the way thru the stud with an 1/8th inch drill bit. It will relieve some of the tension, and also allow you to get penetrant to start working from the inside.
A good drill bit, some lubricant, and the shavings should look like this. If they come out blue, you're getting things too hot, and run the risk of killing the cutting edge of the drill bit. Taken to extremes, this will result in breaking the bit when it won't cut and you start pressing too hard trying to get it to cut.
Once I get to 1/8th inch, I start using left hand drills.
I usually go up in 1/16th inch increments, and most of the time, the broken stud will back itself out.
Sometimes, an extractor is needed.helpfull hints
Use penetrant/lubricant at every machining step.
Your tools will keep their edge longer and operate cooler, prolonging their life and effectiveness.
If the drill bit won't cut, get another that will. You should get curly cue chips when you're drilling at the right speed and feed. (like in the pics) I buy quality
1/16th and 1/8th drill bits in bulk, ten at a time and just pitch them when they don't blaze thru the workpiece. Lifes too short to be drilling triangular holes in slow motion.
Done right, most broken hardware will come out during the left hand drill phase, and you'll rarely need a thread extractor.
If an bolt extractor/easy out is required, use a good
Removing a broken easy out is very
I've always felt that easy outs have a fairly short service life, especially the cheap ones. If you really tweek on them, they wind up, and that's bad bad bad. They are made from a really brittle material, and if you see it winding up STOP
...you're seconds from disaster...
Drill the hole bigger, and use the next size.
You want the extractor to be biting about half way up it's length.
Any lower, and you're on the thinner, weaker section, and you're flexing the whole fluted section.
Any higher, and you're going to expand the top of the stud into the workpiece, making removal more difficult.
If you see any
damage to the flutes, give it the navy flotation test. (toss it in the nearest body of water, if it floats, reuse it.
Good luck, take your time, and good things will happen.