Using a chemical gasket on crank case cover?

[CC07 PEU]

Unfortunately one of the crank case cover bolts on my engine had seized and in trying to undo it I managed to snap the bolt, leaving about one quarter of the bolt in the crank case bolt hole.

The good news is that I managed to drill a perfect hole through the bolt with the aim of using an extractor tool to remove the remaining bolt.

The bad news is that the remaining bolt was so badly seized that I managed to break the extractor tool and that perfect hole I drilled is now filled with the remainder of the extractor bit. I tried drilling this but even the cobalt DeWalt Xtreme drill bit that made light work of drilling through the broken bolt is making no impact on the broken extractor.

It looks like I'm now in massive trouble with regards to getting this engine sealed back up again so that it doesn't leak. I've already tried bolting it all back up again without that one missing bolt but oil is leaking out from the area where the bolt is missing.

Question: can I use a chemical gasket successfully on all or part of the crankcase cover to repair the oil leak? Does anybody have experience of this?

Looks like the bike could end up being a fking write off!

[orangefzr]

Sometimes you can smash the screw extractors out but this doesn't always work and you may end up smashing the crankcases' which would be game over. Is the snapped off bolt into a blind hole ? If not you may be able to knock it out from the back very carefully .... Nightmare job. As the toxic nerve said can you wind it out at all with circlip pliers or something pointy ?

Edited by orangefzr on Sunday 1st April 12:01

[cmaguire]

Good quality photo required

[Rubin215]

Spark erosion is the only thing that will get it out and then you will need the hole re-tapped.

[Ed.]

A mobile mechanic used heavy duty long hex/torq bits which he tapped in with a hammer to remove an sheared bolt for me.
I had drilled the bolt and found easyout not catching.

What kind of easyout is it, a hand winding one or drill attachment?
Could a small socket be tapped on to grip the end of it?

[dc2rr07]

Rubin215 said:

Spark erosion is the only thing that will get it out and then you will need the hole re-tapped.

+1

[AW111]

You may be able to get someone to weld something to the ezy-out or bolt.
The heat of welding often loosens the bolt too, when it cools down.

[CC07 PEU]

anonymous said:

[redacted]

Yes, it was an Easy-Out type of extractor. It was quite a thin one and it's just the tip of it that's now stuck in the bolt... There's nothing really to get any leverage on in order to wiggle it free. The bolt only had an 8mm hex head and the hole I drilled in the remaining bolt was only 3mm diameter.

Doesn't seem like a chemical gasket is an option then?

I'll try and get a photo of it though I probably won't have time until next weekend now