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Okay, I would have to drill it to 13/16 or so, for the external threads. The boss would be weakened, IMHO. I'll use a through bolt for now. The purpose of it is to support the center, pivot point, of the idler arm for the fan belts. A second bolt supports one end, so there is not a lot of stress...

Ryan, I'll check it out as an alternative. The hole is now 5/8 inch dia and no threads.

Got out the remains of the bolt this afternoon. A 1/2" bit snagged it and drove it in and loose. Had to use a chisel to turn it back out. I'm pretty sure a 1/2 inch lefthanded bit would have done wonders. Now, the threads are damaged, so I'll be using bushings and a bolt, which goes all the way...

Who needs rabbit's feet? :-) Found these under the battery box located under the companion seat the other day. May have been there since the day the truck was issued or perhaps a year later. Thirteen cents.....

The current hole is 3/8" and it does go through the bolt. It is a blind hole and about 1/4-1/2" of space beyond the broken bolt (wonder how in the world it snapped off anyhow, defective!?). As mentioned above, the tapered screw extractor is no good, unless there is a lot of material left to keep...

USPS got me the lefthanded bits from Will in record time, only two days from CA. Thanks again Will! The bits worked too well and cut the grade 5 bolt without turning it. I put a so called, screw extractor of the tapered spiral kind in and even used the impact on it without budging the remains of...

Well, as usual you guys are the greatest! Will Wagner is going to lend me a set of LH bits for the project (saves me a lot of driving and checking McMasters, they are not cheap either). I think that using LH bits is the smartest way to go. As far as making this a "sticky", see Kenny, he has the...

Re: RE: Good ideas for screw extraction, please Also a good idea.

I like that Leonard. That's what you used on my flywheel wasn't it? I know it worked like a charm.

A punch, that's an idea, at least it may loosen it up. Thanks Clinto, I have to watch that "beating it in with a hammer" thing, it's a grade 5 in a casting. Water pumps for the dash two don't exactly grow on trees...

There is a washer present, just not a very large one. I'm soaking the broken bolt with a penetrant while I'm considering my options.....

Uncovered what looked like a loose cap screw on the idler arm (image 1), but it turned out to be a brokes grade 5, 5/8 dia bolt (image 2). The broken bolt is in the water pump housing, so if it comes to a worst case, it can be taken off and brought to a machine shop. I have used screw...