Pin Punch snapped off in Bolt

FGT1958 · Aug 8, 2018

I was in the process of stripping the bolt down to check the headspace and as I was driving the extractor pins' roll pin retainer out, the punch started to bend. So I immediately stopped and tried to remove the punch. That is when the punch snapped off. There was a little bit of the punch extending from the hole and I tried to extract it with vice grips. That broke it off the rest of the way.

I ground down the tip of the broken punch and have tried to drive it through, with no luck. Any ideas on how to get this thing out? I hesitate to try and drill it out as the bit is so small. Maybe try to drive it out the other way? In any event, I need a new 1/16" punch!

Inigoes · Aug 8, 2018

Tap/punch it out from the other side, after you oil it.

Let the oil soak in, because you probably applied a little too much force wedging the pin in.

John from MD · Aug 8, 2018

+1 tap it out from the other side. Next, buy good punches. Good punches are hardened and won't peen or bend.

http://www.graceusatools.com/product-catalog.php?category_id=1

jrumann59 · Aug 8, 2018

Buy a new bolt?????

ted76 · Aug 8, 2018

Inigoes said:
Tap/punch it out from the other side, after you oil it.

Let the oil soak in, because you probably applied a little too much force wedging the pin in.

John from MD said:
+1 tap it out from the other side. Next, buy good punches. Good punches are hardened and won't peen or bend.

http://www.graceusatools.com/product-catalog.php?category_id=1

I would try what both of these guys said, plus some mild heating of the bolt, either in the oven to about 400 degrees F. or a couple of minutes with a heat gun on high.

welder516 · Aug 8, 2018

Sometimes with broken bolts , pins and other stuff in holes you may be able to tig weld a nut on top of the broken pin punch and then twist it out . But that is somewhat tricky , but we have done that before on many other items .

Place a small washer down first then a nut on that , weld and cross your fingers .

John from MD · Aug 8, 2018

welder516 said:
Sometimes with broken bolts , pins and other stuff in holes you may be able to tig weld a nut on top of the broken pin punch and then twist it out . But that is somewhat tricky , but we have done that before on many other items .

Place a small washer down first then a nut on that , weld and cross your fingers .

A great trick for many applications and it has worked well for me before. Given the dimensions of this pin, I don't see it happening here.

FGT1958 · Aug 8, 2018

Thanks for the suggestions. I will start it soaking and wait for the short roll pin punches I ordered.

FGT1958 · Aug 8, 2018

welder516 said:
Sometimes with broken bolts , pins and other stuff in holes you may be able to tig weld a nut on top of the broken pin punch and then twist it out . But that is somewhat tricky , but we have done that before on many other items .

Place a small washer down first then a nut on that , weld and cross your fingers .

Easy for you! :lol2:

I'm lucky to get a decent bead with my old mig welder.

clandestine · Aug 8, 2018

If you can't get it out, mail it to me and I'll get it out.

No charge, just pay shipping.

BTW, you did the right thing by trying to remove the Ejector before checking headspace. This particular roll pin gives people fits. So much that I dedicate about 30 mins of my build classes to this one area.

Using the proper punches and bolt vise is critical. Most people use the wrong punches at the wrong time.

John from MD · Aug 8, 2018

clandestine said:
If you can't get it out, mail it to me and I'll get it out.

No charge, just pay shipping.

BTW, you did the right thing by trying to remove the Ejector before checking headspace. This particular roll pin gives people fits. So much that I dedicate about 30 mins of my build classes to this one area.

Using the proper punches and bolt vise is critical. Most people use the wrong punches at the wrong time.

The bolt vise is definitely a godsend to those of us who were only born with two hands. :rolleyes:

FGT1958 · Aug 8, 2018

clandestine said:
If you can't get it out, mail it to me and I'll get it out.

No charge, just pay shipping.

BTW, you did the right thing by trying to remove the Ejector before checking headspace. This particular roll pin gives people fits. So much that I dedicate about 30 mins of my build classes to this one area.

Using the proper punches and bolt vise is critical. Most people use the wrong punches at the wrong time.

Thanks Chad! I remember you talking about that in the Armorers class which was why I waited until I had the vise before even attempting.

I believe the punch was just a hair large. I should have taken a step back when it felt tight, but I thought it was just the resistance of the roll pin.

This sucker will come out....It messed with the wrong old man!

magwell · Aug 8, 2018

Inigoes said:
Tap/punch it out from the other side, after you oil it.

Let the oil soak in, because you probably applied a little too much force wedging the pin in.

It sounds as if you already ordered some new punches. A good set of punches that I would recommend are Starrett # S565WB.

FGT1958 · Aug 8, 2018

magwell said:
It sounds as if you already ordered some new punches. A good set of punches that I would recommend are Starrett # S565WB.

Thanks Magwell, I did. I ordered a set of the Grace punches. I know Starrett makes good measuring devices, but didn't know how good they make punches.

jrumann59 · Aug 9, 2018

Starrett makes some nice staking punches also if you are one to stake a castle nut, or need to stake set screws on gas blocks

E.Shell · Aug 9, 2018

clandestine said:
If you can't get it out, mail it to me and I'll get it out.

No charge, just pay shipping....

Very kind of you, Chad. :party29:

Most people use the wrong punches at the wrong time.

That's how a buddy of mine ended up with his first child.

magwell said:
... A good set of punches that I would recommend are Starrett # S565WB.

I've been using a Starrett punch set like this (but packed in a wooden container) for more than 30 years and have never had to do one thing to maintain them. I have even used them with a brass block with holes of the appropriate size as a die to punch precision holes for scope base shims, etc.. The box shows its age, but, other than a little peening on the back end from the hammer, the punches look new. Starrett makes NICE tools.

Magnumite · Aug 14, 2018

I'll check those punches out. I like the shim hole stamping idea.

FGT1958 · Aug 14, 2018

Magnumite said:
I'll check those punches out. I like the shim hole stamping idea.

Do yourself a favor.....don't buy from Amazon. I thought those punches looked good too. So, I ordered a set. They came last Tuesday. I opened them up and there was no 1/16" punch, but there were two 3/32" punches. So, I returned them and had them replaced. The new set arrived Saturday with, you guessed it, no 1/16" punch...and two 3/32" punches. Apparently packing QC at Starrett is lacking. This time they would only refund me.

And the broken off punch tip is still in the bolt. I used a short Grace punch until it started to bend and it then broke. I sent a message to Grace asking to purchase just the one punch and Dan Morrison, the President of Grace, replied and is just sending me one. That is wonderful customer service.

clandestine · Aug 14, 2018

I have good luck with the Tekton punches.

I have yet to bend or break one myself. Students can be rough on them though.

Magnumite · Aug 14, 2018

I checked the Starrett website. Working out an assortment plus the kit for ‘have to have’ conditions.

Pin Punch snapped off in Bolt

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