When Removing the cross member crossbrace bracket on my 2000 XKR I ended up breaking the bolt inside the bottom front core support. This is next to the hole that you screw the tow hook into to give you an idea on where I'm talking about. I noticed a 2nd bolt broken that looks like it


was done a long time ago. I proceeded to also brake a drill bit inside it as well. Any Ideas? I'm ready to drill an access hole to have a peak inside.

 

There are a number of ways to remove broken bolts. Start with drilling and inserting an easy out if its not really corroded in.The danger of this is that if you break a drill bit or easy out in the hole, it is then much harder to remove due to the hardened steel bit stuck in there. Get a drill bit with a diamond tip or at least a carbide tip and try to drill the thing out. You may have to retap or install a timesert after if you damage the threads.
There are a number of different bolt extractors, just google and select the one that seems most likely to work for you.

The final thing if all else fails is an EDM metal disintegrator. This thing will burn out the stuck bolt, tap and whatever without damaging the surrounding threads. Sophisticated metal shops have them. Hope you live near a shipyard or such with fancy machine shops. Good Luck.

 

I have used cobalt and titanium drills with no success. The broken drill bit in the broken bolt has a titanium tip. I have found a drill bit called RESCUE BIT from amazon which claims to be able to drill thru extractors/broken drill bits. I should get it in a couple of days and I will let you know if it saves the day or not.

 

A friend of mine managed to extract a bolt like that once by placing a nut on top of the screw and fill it with a mig welder. Took several tries apparently, but eventually worked out. Just an idea, never done this myself...