Two broken bolts, bottom of water pump

[dfatherree]

So I had a leak from my water pump on a 1991 Mighty Max with a 2.4L engine and, much to my surprise, it was not the weep hole that it was coming from. Instead, one of the bolts had sheared. While taking it down, a second one sheared, so I now have two studs stuck in the block, one roughly flush and the other about 1/16 to 1/8 of an inch above the surface.
So far, I have tried PB Blaster, penetrating oil, EasyOuts, and am now waiting for my drill to charge so I can try a larger extractor. Anyone have any suggestions or tips to make this process less frustrating? Thanks!

[SubGothius]

If you've got access to a welder or know someone who does, that would be the easy way:
https://www.youtube.com/watch?v=-8N0y0jVAng

[xboxrox]

Nothing much to grab onto ~ these bolt dimensions you gave; are they with the water pump ON or OFF ??

How thick is the water pump material around the bolt (?) removing the water pump will make the broken bolt stub that much longer to grab onto, right ??

Maybe it's worth removing the water pump to get to the broken bolts ?? Seems a new gasket is needed anyway ??

If your dealing with short broken bolt stubs (with the water pump already off) then it sounds like your doing the fix correctly ~ use a file or grinder to make the broken stub end flat ~ continue tapping on a center punch as many times as needed to get the divit in exact center ~ always drill slow & turn slow ~ broken easy outs are even more difficult to remove !! Start by using small diameter drill bits then use larger size drills helps too...

If there is room ~ a Dremel tool with a small tungsten carbide cylindrical shaped end cutting bur will be able to remove most of the bolt material ~ then, an easy out, pick or machinists scribe can remove the remaining material

Good Luck with the tedious fix & finish the job by using a tap to chase 'n clean the threaded holes ~ use Q-tips dipped in laquer thinner WD40 or any cleaner to clean the threaded holes ~ use anti seize & new steel fasteners IN ALL THE HOLES -- CHASE THE THREADS IN ALL THE HOLES -- REPLACE ALL THE FASTENERS !! In my best Joe Biden voice: "NUKE IT OUT MAN" !!

Let us know how well it came out OK ?? :thumbup:

[dfatherree]

Hey guys! Thanks for the replies.
I ended up using a guided 5/64 drill bit (really cool thing that I had no clue existed!) to center my drill on the studs and drill a starter hole. I used gradually larger bits until I could get an easy-out to bite on them and pulled them right out.
Here's a pic of the two offending bits of bolt:
http://www.mightyram50.net/vbulletin/attachment.php?attachmentid=26585&stc=1