CityCyclingEdinburgh Forum » Stuff

Snapped brake lever bolt (or: I'm an idiot)

(8 posts)
  • Started 10 years ago by allebong
  • Latest reply from allebong

No tags yet.


  1. allebong
    Member

    I'm sure many of us have had the experience of successfully carrying out major maintenance and part fittings, only to make a complete, embarrassing mess of something extremely simple. Here goes..

    I picked up a rear hydraulic disc brake secondhand for a mere tenner. It has a split clamp lever, which is meant for you to be able to put it onto the bar without taking off the grips etc. Quite clever, but as this is a mtb brake, and mtbs now practically all use lock on grips which come off in seconds anyway, it's not as useful as it was in the days of stubborn slide on grips.

    Still, I've used these before without incident, so I cleaned off and greased the somewhat rusty clamp bolts and began tightening it down.

    OH SNAP! Literally.

    I believe I tightened one of the bolts too far before doing the other one to balance the load. That bolt had bottomed out in the brake lever thread, jammed and then promptly snapped as I done it up 'just a bit more'. There was a few mm of thread sticking out which I thought I could weasel out with pliers/vice grips, but all I've achieved is mangling it further - it's definitely firmly stuck in there now:

    Am I right in saying this is still salvageable if the bolt can be drilled out? The threads must still be intact so if the old bolt can be gotten out it'll still be useable. Is this the sort of thing a bike shop will be able to sort? I'm kind of hoping it can be done easily and cheaply as the purchase of this brake was meant to be on a strict budget....

    I suppose I can think that it's better for it to have broken when installing than when in use. I've not had this failure before so I'm tempted to think the previous owner might have overtightened the bolts and left them weak.

    Posted 10 years ago #
  2. I were right about that saddle
    Member

    Rats, eh? Nothing worse.

    I have a set of stud extractors that might get a hold of the end of the snapped bolt. PM me if you want me to have a go at it.

    Failing that, soak it in WD40 overnight, file a flat on the stub, heat the body of the clamp and twist away with mole grips.

    Posted 10 years ago #
  3. tk
    Member

    Sometimes sawing a slot in the stub and using a decent screwdriver will work with plenty of WD40. Alternatively drilling a small hole in the bolt and using a set of tapered reverse screw extractors should do it. You basically create a thread in the anticlockwise direction screwing the extractor in while unscrewing the bolt.

    Posted 10 years ago #
  4. Roibeard
    Member

    I've managed this situation in an engine block. It required a weekend to calm down...

    So, I've also got the required reverse thread tapered mewhojits, and the experience of taking a drill to my engine to get a hole started for the mewhojits [1].

    What I don't have, so a workbench with vice which would be required to hold the assembly for the tools to do their work - but you're welcome to a loan of the tools.

    Robert

    [1] I think they may actually be called "easyouts", but what do I know!

    Posted 10 years ago #
  5. allebong
    Member

    Thanks, seems there is hope after all - I'm not in a great hurry to get it fixed at least and have the old brake on standby if needed.

    Think I'll order in some penetrating oil (could certainly use it for a few other things as well) and see what that in combination with heating will do. I can apply a fair bit of torque to what's left of the bolt with vise grips so maybe that'll be enough. Might also try sawing in a slot and screwdrivering it out.

    Posted 10 years ago #
  6. allebong
    Member

    Well, looks like I'm defeated, and it's almost time to call it quits.

    Penetrating oil had no effect. Heating had no effect. I filed flats onto the stub and got a good grip. All to no avail. It really is like the remains of the bolt are welded in there, absolutely no sign whatsoever of it budging, and I even went so far as to check I was turning it the right way before doing all that!

    I took a hacksaw to it figuring if I got a bit of the clamp off it might free up the threads or at least expose them enough to try something else. No luck, and all I have now is a semi-mangled clamp face with the bolt now flush with the surface. It's probably now possible to try out the reverse thread extractor doohicky majig though I'm questioning how practical it is. The bolt is awfully thin and it seems that even with a vice you'd struggle to get it in, and as I said it is very, very firmly stuck in there, I think you'd end up snapping the extractor before any sign of movement.

    One last chance - I found I have a half decent drill knocking about in the shed, though curiously no sign of any drill bits, go figure. I'll get some in and try holding the thing in a C clamp or something and drill out the bolt. There's no way I can make it worse by trying.

    In the meantime, the old cable brake is going back on the bike, there was nothing particularly wrong with it except me thinking a hydraulic disc for £10 was a bargain - which it is, and would be moreso if I hadn't made such a farce of installing it.

    Posted 10 years ago #
  7. I were right about that saddle
    Member

    I feel your seized fixer pain. At least you've given in before the final, darkest hour: the moment you actually consider buying one of these;

    http://www.stanleyengineeredfastening.com/brands/heli-coil/screw-thread-inserts

    Posted 10 years ago #
  8. allebong
    Member

    So you're not left in the dark and this thread has a 'satisfactory' conclusion...

    It's wrecked. Got so far with drilling it out, then ended up mangling the clamp rather than the last remnants of the bolt. It's now well and truly stuffed beyond the help of anything.

    Now, if I hadn't snapped it on install, it'd be fine. If I'd maybe got a stud extractor and used more penetrating oil, it might have came out. If I'd gotten it to a machine shop, they might have drilled it out better. If I'd....etc etc, usual post screwup routine.

    Ah well, for a tenner I'm not devastated. While the old brake was off I gave it a quick adjustment and it's working pretty well now.

    Probably time I got round to getting a torque wrench though, that would I suspect have prevented this in the first place.

    Posted 10 years ago #

RSS feed for this topic

Reply

You must log in to post.


Video embedded using Easy Video Embed plugin