So...

How to extract an extractor form a broken rusted bolt? Then still remove the broken bolt. Without welding/plasma cutter.

I tried cutting it down smooth and drilling again, but the extractor is harder than the bit. The bolt is on the front right fender, rear lower retaining bolt. Someone spot welded the fender to the nub instead of removing it.

 

Can you get to it with a sharp punch and hammer to try and turn the extractor out? Are you wanting to remove your fender or what?

 

I had to pull the heater core, I got the fender off (enough). I am just wondering how bad it will be without the second bolt holding it on if I cant get it out.

It is a straight blade extractor, and I pounded it in good. I was off center when it went in, so I think I will see if I can get another hole started in the bolt. I have a feeling I am just going to end up with a swiss cheese bolt and it will still be stuck though.

 

Is there enough of a nub to grab with a vice-grips?
Have you seen this stuff...http://loctitefreezeandrelease.com/
You then might be able to spin the bolt out with a hammer and small sharp chisel.

 

There was, but it was no good. I thought it was moving a bit, I tried to go back and forth and it was just rust I heard flaking. I ground the nub down to try and re drill after the extractor broke. I'll check that link out though.

 

Funny, I used some canned air the other day to get a nut off the power steering pump. I gave it some heat with the torch then froze it with the can air upside down. I will give that a shot, didnt think it would help the blaster get up in there.

 

If the extrator is a good one it is hardend tool steel. You will need a carbide bit to even have a chance. The carbide bit will not be happy about the movment of you hand drill. Can the assemble be taken off? Maybe set up on a drill bit. Normally once a pc of hardend tool steel brakes off in a hole we use a EDM hole poper to burn it out. Careful with any torch melting steel may not work out like you think.

 

I will hack off on this again this weekend. Thanks for the ideas. I'll post the results. (complete failure I'm sure, but I'll work something out)

 

carbide bit is the only way your gonna get it out, most autoparts or regular hardware stores will not have them they are costy but will do the job

 

I haven't had a chance to try that Loctite Freeze stuff yet, but I want to. If it works like it should, it would save you from a hard fight. The concept is that the extreme cold would shrink the bolt just enough to crack it free. And it's safer and less damaging than a torch.