I have one more try for you to get
the bolt out if I am not too late. Get yourself an extraction set that is comprised of left hand twist carbide tip drill bits and bolt extractors. Pre- soak the bolt with "PB Blaster". I think Hanson is the name of the kit, check with a machine shop and ask them for a source. Grainger or McMaster Carr may have them in their catalogues. Then get a drill that has a forward and reverse on it. Take a really good center punch with a very clean and sharp point and get a really good starting point with the center punch. Take the really small bit and turn the drill on in reverse so that it is turning in a counter-clockwise direction and drill a small pilot hole and gradually increase in bit size. Make sure that you keep true to the centre of the bolt and the broken easy out that is in it. Just take your time and let the bit do the work, don't bear down too hard on it and dull the bit, let it do the cutting. Use a cutting or tapping fluid to keep the bit clean and take your time and go slow, let the bit do the work, not your arm pushing on the drill. If you are carefull, you may get lucky and be able to catch the bolt/broken extractor on the side of one of the larger bits as you increase in hole depth and have the whole mess back out. As you increase bit sizes, you will reduce the ammount of remaining material in the original hole and it will break loose and come out or you can use the extractor and get what remains out. If you keep increasinig bit size and hole size, eventually there will be nothing but a fraction of an inch and material remaining in the threads of the original bolt hole and this will basically fall out. Clean it up with a bottom tap and you can get a new bolt and be good to go. If you damage the threads and you can't dress them up with the tap, drill out to the next size up and then tap that new hole and use a larger bolt. You can do this if you take your time and concentrate. I've done it many times and saved myself a lot of work and money and time. If you pull everything down and take it to a machine shop, then make sure to stand around and watch the guy do exactly what I have indicated here to do. Then the next time it happens you will have at least seen it. But, I am confident that if you do this, you will be successful. I'll be interested to hear how it comes out for you. Good Luck, Tom PS A little bit of heat, like with a heat gun or a good stout hair dryer on the material outside of the broken bolt will help that material expand a little, just enough to reduce the clamping pressure that is being exerted on the bolt, just try not to get the bolt hot by staying well to the outside of the hole and the surrounding area ro the bolt will expand which is not the objective.
