Bolt sheared off thermostat housing

lightning · Jul 10, 2017

My mate has bought himself a Series 2a (l think) fitted with 2.25 petrol engine.
He's tried to replace the thermostat and sheared of a bolt in the casting.
He's tried to drill it out and then put a bolt removing tool in the hole he drilled, which has snapped off in the hole.
Where to go from here? He's a bit stuck now! At least access is easy....

jamesmartin · Jul 10, 2017

it was bound too its only a 1/4 bolt , id take it to your local engineers not a landy place

lightning · Jul 10, 2017

Problem is getting it there, he lives out in the sticks

jamesmartin · Jul 10, 2017

you can try smashing it out a decent punch and air line or vac

Shifty1962 · Jul 12, 2017

Find an engineering works with a "spark eroder". It will take out the hardened extractor and the remains of the bolt without touching the casting. It takes time but works. I'm lucky in that I have a very good mate who has just such a tool in his workshop. It is always busy and earns him a pretty penny.

Colthebrummie · Jul 12, 2017

Could try grinding down a chisel to fit in the hole if the remainder of the bolt/stud isn't proud and cutting a slot in the top to then try a sturdy, flat bladed screwdriver. The chisel impact may loosen it up. If the bolt is proud, try welding a nut on it

Col

lightning · Jul 12, 2017

Thanks l'll pass on these ideas to him.

Bolt sheared off thermostat housing

lightning

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jamesmartin

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lightning

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jamesmartin

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Shifty1962

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Colthebrummie

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lightning

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