Drilling out Arctic Cat helix bolts Help
 

Got a sled yesterday with a bad secondary. Got it home and figured out what was wrong. Got everything in good shape now other than extracting the three broken off bolts in the helix. Tried drill-press and with the small bit it just wants to bend the bit. Tried heat with a pick and that’s a no go also. Any ideas. Yeah I know I come across some fked up chit bit Tks in advance.
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try setting a small nut on top and welding it to the broken off bolt.

Got get a carbide drill bit...about 5/32", it will drill through that like butter, then you can use a screw extractor (Easy-Out).

yup, and weld won’t stick too the aluminum.

https://www.ebay.com/itm/122978410906

Don't waste too much time on it! That is a wear item, and they are easy to come by

make sure its a reverse drill bit

welding a nut is the easiest method of extraction,,do it all the time.I only drill if I need to shrink the bolt as its being welded.

I have removed more broken bolt with left handed drills than any extractor I have ever tried.

I’ll try the left bit. Two of them are down 5/16” so welding those two not fix unless I’m not a good welder. Tks

Could you drill it out bigger and retap as a last resort

might have to do that. Worse case I’ll buy another but have some time so I thought I’d ask. Tks. I have a shelf of old stuff an I do have a 48/40 but not sure that’s close.

Anybody mention welding ?

So this damaged one is a 44/40? I see looks like a diamond drive helix, z1 turbo, firecat or f sled? a 48/40 might be a little tall unless your a really light rider or drag racing. BTW, the 10'/10.4" diamond drive clutches are rare AF right now, BDX hasnt been able to get there hands on one in 18 months so all new ones are gone from all shelves, used ones are few/far between and disappearing and newest thing is my one snowmobile parts wholesale supply DROPPED the BDX 10.4 clutch part number thats been showing back order, says BDX is dropping the part#, the Z1 turbos eat one of these about every 3500 miles when turned up!

Getrdunn,

Take it a machine shop that has an EDM drill or a sinker/post EDM. They will burn those screws out with zero damage to the part, and they likely won't charge you much. Consider the cost of replacing what would appear to be an unobtainium part.

If you get into a bind, we can make arrangements for you to send it to me. I've got a shop around the corner of my building that has the EDM drill, and he would do it for me for nothing.

Thanks. Brad.
(937)545-8991

Soak with 50/50 mix of ATF and acetone.
Then drill center and use EZ out as mentioned.
The penetrating solution will help if there is any corrosion or thread locker helping hold the broken pieces in there.

It is a diamond drive helix off a Firecat. I’ll put the 48/40 on till I get the other one to a shop. Pretty sure the worn rollers put to much strain on it is what caused them to brake. Already replaced those. Pretty small bolts for the purpose. I did soak last night 50/50 and see this afternoon but so damm hard to get a hold of the bolts with anything. I think burning them out be the best solution. Never thought of that!

Has anyone mentioned welding ?

Getrdunn,

I'm a toolmaker. EDM is my first go-to whenever I break a tap/drill/screw. Like I said, I have a couple options for resources on this front. Let me know if you hit a wall.

Something else to consider if this is a recurring issue for you... Nitric acid will dissolve steel while leaving the aluminum unscathed. Most lab supply companies sell it. A small QTY will last you quite a while and won't cost much. Just a thought.

Thanks. Brad.
(937)545-8991

Even though the bolts are below the surface, it is a very easy job to build them up with a mig welder and weld a nut to them to remove them.

Just thinking out loud

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I second the EDM. When I was fixing sleds and any small motor stuff I used EDM regularly to burn out bolts. I had a key way break on a kart racing engine and had the crank welded and burned a new key way with EDM, worked perfect. Other option is to use a center drill from a lathe or mill they are very hard and won't move even when drilling on an angle like your broken bolts. Just make sure everything is clamped down super tight.

Had the joy of plowing all day when everything just goes perfect. 😂. NOT! I’ve got a plasma cutter and tig/mig welder. My favorite shop must along with welt band saw. I put the 48/40 on for a quick fix and pulled it over 3 times and the fken pull cord broke. Just the way chit goes. Rewound with new rope and pulled over twice and didn’t retract. The way it goes… Tks for all the input.

anybody mention welding.:D :D

Weld a nut on the broken bolt?

Thinking about this for a bit, I’ll have to agree.

yep, it does at least two things, first it gives you something you can put a wrench on and secondly it thermally shocks the broken( most likely corroded) and stuck bolt . Works great but I've never done anything as small as a helix.

Anyone ever weld out a pressed in bearing race?

run a tig arc around the race and it should fall out,,thats how I take out valve seats.

Good to know these things!!!

Have you tried the liberal use of high explosives???

😂

The easiest way to fix an Arctic Cat...
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Rookie,

I'm not into sleds, but that's funny right there, I don't care who ya are....

Thanks. Brad.
(937)545-8991

Haha 😂. I do get sick of looking back all the time so point well taken! 👌

Yeah, I understand. You never know when the truck and trailer are going to drive by to pick you up alongside the trail. You don't want to miss seeing them. It gets cold out there when your not riding... :)

This snowmobile thread went on too long without some trash talking. It just didn't feel right. (I normally do not talk trash, this was just good ribbing) But, out of all the forums I belong to. The snowmobile forums have the most trash talking, brand bashing mofos of all. It is mostly just witty banter, but sometimes it's relentless. It makes a Cigarette vs Fountain thread look like childs play.
If you know, you know.

Rookie,
Oh, I get it. I just appreciate a good jab. Gotta give props when props are due. :lolhit:

Thanks. Brad.
(937)545-8991

I had it coming! 😂. Just glad to enjoy winter also. 🍻

have you gotten the god damn bolts out yet.:D