Progress...

So, for the last couple of weekends I have been trying unsuccessfully to get those broken bolts out.

The last couple of weekends have seen me trying to get the bolts free by heating & cooling and soaking and soaking them with penetrating oil. And heating & cooling & soaking. And heating & cooling & soaking...

Anyway, the two that are sticking out ain't budging. I tried using an extractor to dislodge the one that broke off flat. That requires drilling a hole through the center of the bolt and twisting in the extractor. The extractor has left hand threads that are supposed to grab onto the bolt and twist the bolt out.

As you may have guessed, the extractor broke. Now, the extractor is made of really hard metal, and drilling that sucker out is a pain!

Okay, so I get fed up trying to unscrew the bolts and decided to just drill them out. After some trial and error, I found the best tool for that is a Dremel with a bit for cutting tile. It is a rough bit and is good at grinding the bolts out of the holes.

After that, I used a tap to clean out the threads on all the holes, starting with the ones the bolts actually came out of. One of those had threads that were crushed for some reason, but I think I have got it tapped so it will hold a bolt.

Then I managed to break the tap on one of holes with the stick bolt. Drilling that out sucked - took me most of the afternoon today, and that hole is pretty ugly now.

So, next weekend I am going to work on cleaning up the holes that had the stuck bolts. I'll see if I can retap them, but I think I'll probably have to install an insert to restore the threads.