Step-by-step:

Preparations and safety procedures:

• Wear suitable eye protection and gloves to protect yourself from metal fragments when drilling.

• Never use the bolt extractor on live electrical components or in explosive environments.

• Ensure the bolt and surrounding area is clean of debris using a wire brush and/or compressed air.

• It may be necessary to use heat around the bolt or penetrating oil to help the removal, but make sure the drilled hole is free from any metal fragments and contaminate free to ensure a correct fusion occurs.

• Check the bolt size matches the correct size chart from M6 – M12.

• Store the tool in the supplied tool case in a dry place to help prevent damage and corrosion.
• The fusion creates heat and can burn skin if touched.

Instructions:

1. Use a centre punch to mark the centre of the bolt or stud
2. Drill a pilot hole through the CENTRE to approximately half the width of the broken stud at 90 degrees – for example drill using a 4mm drill bit for a M8 stud (Make sure it is drilled centrally)
3. Using the tapered reamer, ream to profile the hole to the correct shape on a low speed drill setting (please note: the reamer cuts in an anti-clockwise direction) Remove any metal fragments after
4. Ream until the mouth of the hole is nearly touching the threads of the suborn bolt or stud, (use cutting oil to prolong life of the reamer) again remove any metal fragments and make sure the hole is contaminate free
5. Once the hole is the desired size, use a hacksaw to trim the tip of the mandrel to ensure the largest amount of surface area is in contact with the broken stud – ensure it does not bottom out!
6.  Fit the tapered mandrel into a sufficiently high torque drill (recommended minimum torque 120Nm – anything below will stall), set the speed high and the rotation required for the thread direction
7. Insert the mandrel into the hole, apply hard downward pressure and pull the trigger
8. The mandrel will self-weld to the inside of the suborn bolt and will wind out with the rotation

 If for any reason the attempt is unsuccessful, the mandrel can be drilled out easily to repeat the procedure once again.