SuzukiSavage.com - 2 broken brake disc bolts

Serowbot

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Re: 2 broken brake disc bolts - oops
Reply #15 - 10/12/12 at 09:28:37

First off,... DD says he did use an allen head socket...

second off,... I believe the same twisting forces are applied either way....

third,... that said,... I am able to get more downward force on a rachet at the same time as twisting... which is helpful...
so, I still recommend the sockets...

Lastly,.. those are some weird bolts.... they never loosen as they turn...
It's like you are still trying to break them loose throughout the length of the treads...
I've done two rotors,.. and every bolt was like that...
Those bolts were too hot to hold when I got them out...
So glad I have an impact wrench... Wink

...

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Boule’tard

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Re: 2 broken brake disc bolts - oops
Reply #16 - 10/12/12 at 11:01:34

Well see, you DID use heat to get it out.. sort of.. Cheesy

Which reminds me of another episode of hex bolt hell. So I'm trying to refurbish Paw Paw's old chipper/shredder machine, and there's a heavy steel disk with a blade bolted onto it with hex bolts, loctited in. Of course on the last bolt, the allen wrench balled out, and then broke in half after I welded it into the bolt. Then I welded a larger piece of steel to the head and grabbed the back end of the bolt with vice grips, to apply additional torque. So.. two heatings and gobs of straining on both ends, and it finally came out.

Needless to say, the chipper now has new bolts done with BLUE loctite, not the red stuff.

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Cavi Mike

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Re: 2 broken brake disc bolts - oops
Reply #17 - 10/12/12 at 11:18:50

Just using a socket has nothing to do with it. The point is to get yourself away from the bolt so you're forced to support the other end of the wrench with your other hand. This prevents the unwanted force from being transferred to the bolt. That is why I said and I quote:

Cavi Mike wrote on 10/11/12 at 00:57:11:

You should always use something that can only turn the bolt. Something like .... a ratchet WITH A 10" OR LONGER EXTENSION.

Using a ratchet with no extension is no different than using a hex key. You're using the bolt to prevent the tool from cocking sideways instead of your other hand.

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28653 Tucson Az Gender:	Re: 2 broken brake disc bolts - oops Reply #18 - 10/12/12 at 11:26:59 Never thought about that... good point... I don't even have a 10" extension,... but I do often use a 6"... Cavi,.. you're costing me money... ... May have to buy a couple of 10"'s... ...
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DrunkenDwarf

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Re: 2 broken brake disc bolts - oops
Reply #19 - 10/14/12 at 22:03:33

Starting this project myself. So far the center drill bits I bought to make starter holes for the left handed drill bits are making slow work of the bolts. I screwed up a little more, I didn't have anything hard enough to make a good mark to keep the center bit in the center of the bolt, so I'm a bit lop sided. Will have to use a smaller left handed bit than I was originally planning.

The adventure continues tomorrow night.

-D. Dwarf

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Pearl White 2007 S40; Dyna exhaust; Current jets: 52.5 w/ bleed (2 turns out) / 1.5mm (0.06") spacer / 150; raptor petcock

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justin_o_guy2

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Re: 2 broken brake disc bolts - oops
Reply #20 - 10/15/12 at 05:03:57

I hate to see you headed into that DD.. I wish you well,, but I think youre walking into a bear trap & that for $40.00 or less you could get out of trouble. The bolt broke because there is something in the threads, right? Whats gonna make the bolt turn easier after youve drilled it?If youre gonna wind up in a machine shop, Better to get there before its a mess. Unless youve got heat, you kinda need to be able to focus some heat on those bolts, dont you? To kill the Lock Tite? Id want a brazing tip.,A Mapp Gas canister with a torch head on it would get it plenty hot, but thats gonna heat up a larger area..I wouldnt want to just hold a big fire down on my brake disk/axle area.
Setup for an ease out is crucial. Off center drilling, holes drilled at an angle, just makes it harder. I am all for doing things yourself, but there are times when its best to just call in reinforcements.If tooling to get a hole centered & square isnt on hand I would haul it & pay someone,
Best of luck, man, either way. Keep us -posted.

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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: 2 broken brake disc bolts - oops Reply #21 - 10/15/12 at 08:50:26 I've got a heat gun. Going to give it one shot. If it doesn't work I'll take it to a shop. -D. Dwarf
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: 2 broken brake disc bolts - oops Reply #22 - 10/15/12 at 09:39:06 A $10.00 propane soldering tool from Lowes will lay more heat into a bolt than a heat gun. AND youll have a new tool.. Its one of my favorite soldering tools. I take the tip off & use the flame tip.
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DrunkenDwarf

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Re: 2 broken brake disc bolts - oops
Reply #23 - 10/16/12 at 12:33:17

Took it to the shop. 1 bolt came out fine. 1 bolt my pilot hole was too off center and we lost some threads. Sad

Shop guy said it would hold, just use about 3/4 torque. Your thoughts?

If decide to replace the hub, what do I need?

Part # - Description
54111-24B01 - HUB, FRONT
08123C63027J000 - B1 15X42X13 BEA
09180-15074 - SPACER, HUB BEARING

Can I get the bearings out of the current hub? Is that asking for another world of hurt?
How much pain is relacing going to be?

Learning is so painful.

-D. Dwarf

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Pearl White 2007 S40; Dyna exhaust; Current jets: 52.5 w/ bleed (2 turns out) / 1.5mm (0.06") spacer / 150; raptor petcock

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28653 Tucson Az Gender:	Re: 2 broken brake disc bolts - oops Reply #24 - 10/16/12 at 12:44:09 Them bolts go in tight... if you get it in without stripping completely,.. my bet is, it will stay... .. or,.. if it strips,...leave that bolt out... there's still plenty of bolts holding the disc... (I realize this advice should have an idiot warning)... but, that's prolly what I'd do... ...
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: 2 broken brake disc bolts - oops Reply #25 - 10/16/12 at 14:52:39 Id put it together, use Blue Locktite, Check it periodically & if ya cant do that, then at least look at it every now & then.. Its gonna be okay, Ill bet your life on it..
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DrunkenDwarf

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Re: 2 broken brake disc bolts - oops
Reply #26 - 10/16/12 at 21:17:30

Answered one of my own questions. Clymer's says you'll damage the bearings if you try to remove them. So new bearings it is. Has anyone built the bearing installation tool out of parts? Maybe I should start a new thread.

~~How about installing spokes, anyone got advice on that?~~
Found this:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1302363211

-D. Dwarf

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« Last Edit: 10/16/12 at 22:33:23 by DrunkenDwarf »

Pearl White 2007 S40; Dyna exhaust; Current jets: 52.5 w/ bleed (2 turns out) / 1.5mm (0.06") spacer / 150; raptor petcock

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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: 2 broken brake disc bolts - oops Reply #27 - 10/17/12 at 12:41:48 Would an electric impact wrench have prevented these from breaking? Found some used front wheels on ebay for about $100. That seems like the most reasonable solution. -D. Dwarf
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: 2 broken brake disc bolts - oops Reply #28 - 10/17/12 at 12:52:11 These come on for $50 + shipping all the time.
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DrunkenDwarf Senior Member Offline Morning Zombie Posts: 325 Seattle, WA Gender:	Re: 2 broken brake disc bolts - oops Reply #29 - 10/17/12 at 13:20:00 verslagen1 wrote on 10/17/12 at 12:52:11: These come on for $50 + shipping all the time. Any 'gotchas' to look out for? -D. Dwarf
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