So after I did my fork lowering,  I went to put my front fender on and the last screw I put in somehow busted off and was stuck in the fork.   I tired using a screw extractor today,  I had the hole drilled through and I put the extractor in and hammered it in good,  and I went for one more but with the hammer and if busted off in the same spot,  and now this metal is even harder then the forks.   I spent 2 hours with a drill and nothing...  I actually went to a specialty store and got still bits meant for going through hard metal and nothing.   So I don't know what to do.   I'm not going to run a front fender with just three screws,  and I tried everything,  I even drimmeled into the fork trying to get it out with a flat head.   Am I going to have to go to some shop just to have a bolt removed   or rather a bolt extractor removed now,  or would it be better to have it drilled to a larger diameter and rethreaded?   Please help! As you can see from the picture,  I made a mess of things,  but I plan on painting my lower forks so I figure I can put some sort of filler in and paint over it...

ToesNose wrote on 04/12/14 at 04:43:49:


But I need to have mine drilled and tapped,  that's the main issue.   I'll deal with getting it filled once I can actually get a screw in there.   Until then I can't run a front fender...

I usually remove broken bolts or studs by welding a nut to it.The heat from the weld help to loosen the bolt.
With the welder i dont use easy-out anymore, except for grease fitting.
Marc