Drilling Out Bolts
 

A few weeks ago, I decided to remove my bedliner to see about any rust that was under there. Well, to remove the bedliner, I had no choice but to remove the tie downs.

Unfortunately, three of them broke off and another had to be drilled off enough for the head to lob off.

Well, a couple small purchases later and I've got what I need to correct this problem. 1/4-20 tap, matching bolts and four eyelets to not only reinstall my old tiedowns but to get an upgrade at the same time.

But..... There's a problem. While I was able to quickly and easily drill out the holes where the bolts had been removed (to tap them to fit the new bolts), I can't seem to cut through the bolts which broke off in the threads. I even spent three bucks on a titanium drillbit (albeit it was rather cheap) and that did absolutely nothing.

So, before I potentially waste more money, what on earth do I need to drill out these bolts? Also, I considered trying to use a bolt extractor, but they're just so rusted i'd be more likely to break it off in the bolt than actually remove it.

First, always use Reverse drill bits when trying to remove broken bolts.
It drills like a regular drill bit but also has the added advantage of unscrewing the bolt if it catches, also the vibration of drilling helps that along

Many broken bolts unscrew using just the Reverse bit.

Heat probably isn't an option because of the location, so about all you can do is drill them out.
It can take some time, use lots of oil, start off with smaller bit size to get some material out of the center and then move to larger sizes.
And yes if it is that rusty then you may have to drill out the hole and retap it at larger size.

Heat kills drill bits, dulls them, so use oil to cool bits constantly

Didn't know they made reverse drill bits. I'll have to see if I can find one.

They are cheaper, per bit, buying a set, and they are almost always hardened steel because their main, if not only, purpose is to drill out broken bolts.

Not mentioned but you also need a reversible drill.

http://www.amazon.com/s/ref=nb_sb_noss_1?url=search-alias%3Daps&field-keywords=reverse+drill+bits



http://www.harborfreight.com/catalog...and+drill+bits