So here’s my predicament: I’ve got a 2009 softail custom I’ve been fixing up here and there for a while now, and one of the issues I’ve been putting off is trying to fix a broken bolt underneath the bike. On my low side shock, the bolt that holds in eye to the frame is broken off approximately 1/2 inch recessed into the hole. Now, there’s isn’t any clearance to weld another bolt onto the broken stud, and even if I could there’s barely enough clearance to remove the
bolt under normal conditions, let alone this bolt specifically as it is old and rusted to ****. Does anyone have any suggestions? Because I’m considering cutting off the entire thing and fabrication is new, but I’m not very good at using a tap and die set so I’d prefer to avoid that.

 

Google "screw extractor" ?

 

That bolt could be a hassle to be sure.... you may need to spend some time removing parts to gain access..

I suspect, and suggest, removing parts for access, would be better than cutting a major load bearing portion of your swing arm... unless of course you are experienced in metal fabrication and repair... In that case, I would think you would remove the swing arm before attempting metal fabrication to the swing arm anyways...

In case you didn't notice, the eye bolt of a softail shock bolts into a mount/bracket, on the swing arm, not the frame.

You will need the minimum of a scissor jack to raise the bike up a little to work on it. Then hopefully manipulate the swing arm to gain access to the broken bolt, after removing the shocks...

If there is no way to get access, on a scissor jack, with the shocks removed, and by moving the swing arm up or down.... Remove the rear wheel. See if you then have enough movement in the swing arm to gain access to that broken bolt...

If you don't have enough room with the rear wheel removed, then you'll need to remove the swing arm. With the swing arm removed, you can use a bench/vise/whatever and have unfettered access to that broken bolt...

Once you have access, you can do the weld technique if you have that knowledge & equipment..... Since I don't have welding tools/skills, I'd use heat and then an easy out...

Good luck and report back how you end up fixing it...

 

If you drop the swing arm as suggested above: Can you drill it out from the opposite side ?

 

Left hand drill bit, lots of heat and extractor would be my first port of call.

 

I appreciate the advice, i
think I’m going to end up just removing the swing arm altogether, using a grinder to cut off the bracket, and making a new one to weld up instead. That way I know the threads are brand new, and not old and rusted. I need to do some work to the rear end anyways so I’d be removing the tire regardless, seems like a good next step. Thanks guys, I appreciate it

 

Ever try the copper tube method? Small copper tube like brake line into the hole. Fill with weld. Then a nut on top. Copper insulates and doesn't get weld on the threads. The heat from from build up does wonders and they usually turn right out. Done it many times on broken exhaust header bolts.

Also pretty amazed with "Speed Outs". Might be worth a try first. Penetrating oil, heat, and one of these has saved me a few times.

 

^ Bloody Genius ^ if it works
Never heard of that one

 

Harley Davidson engineers working on new bolt formula.

 

For your viewing pleasure,