There are four different ways I've broken bolts in the past.  

1.  It's not threading in correctly, and I imagine that I'm using the bolt 
to clean out the threads.  I'm forcing it and it breaks off.  I should have 
tapped the threads first.  This also happens when you cross thread, or use 
the wrong threaded bolt for the hole.  
2.  It threads in correctly and but I get to the end of the threads and 
it's almost there, but not quite tightened down on the assembly.  I force 
it and break it off.  I should have just used a shorter bolt
3.  It threads in correctly and bottoms out fine and I just overtighten 
it.  I shouldn't have been so strongarmed
4.  It threads in fine and tightens down fine, but it breaks when I try to 
loosen it.  I should have greased the threads

Do you know which of these four you did?  Or something else?

Bill Lindsay
El Cerrito, CA

On Monday, March 21, 2016 at 8:14:42 AM UTC-7, Joe Szokoli wrote:
>
> I wondering if anyone out there can help. I'm building a Randonee bike up 
> for a friend and I have a big problem. I've broken a bolt off in a brake 
> boss, and then in hindsight, stupidly an ez-out as well.  As I've been told 
> by a couple of people, never think that a ez-out will work, NEVER ever go 
> that route.
>
> From my understanding fixing this mess is a job that a EDM / tap burnercan 
> do. But I have had no luck locating anyone locally that can do the work. 
> Does anyone have someone they could recommend?
>
> Thanks you for your time,
>
> -- 
> Joe Szokoli
> New York City
>

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