Broken stud removal?

[GTVeloce]

I am a little stuck. Have pulled a pair of Brembo front callipers apart to rebuild them and one of the bolts sheared off leaving a chunk of the thread in one half of a calliper. I bought a set of easy outs to try to remove them but had lots of trouble drilling a pilot hole and then the first easy out I tried snapped when trying to get it in. I'm guessing the bolt is high tensile which is making it difficult to drill and tap. Any thoughts on how to get this broken piece out?

Secondly, any idea where I am going to be able to source a replacement bolt?!

[Citroënbender]

Thread repair workshops can often do stud and extractor removal.

An old schooler could usually burn it out with oxy, else if you're brave start from the opposite side with a 1/16" drill and be sure to get it centred, once the hole is 2-3mm deep step up in sixteenths until you are almost at the thread minor diameter. Then progress slowly in drilling, making sure to stay square to the thread axis and on centre until you just contact the easy-out. It can now be punched free.

[bonno]

Hi GTVeloce
The use of spark erosion machine will disintegrate broken bolt, without damaging threaded hole. This service can be provided by your local tool making shop who specialising in jobbing work.  The replacement bolt can be sourced from wrecker or AR dealer.
Cheers
bonno

[GTVeloce]

Thanks for the replies. I am going to take it to a professional and let them do the work. A little more research plus the comments provided have made me feel I probably don't have the skills and tools (a bench drill would be pretty handy for this job...) to do this job and certainly without spending many hours which I don't have.

Time to pass it onto an expert.

[LukeC]

I have long had the opinion that "Easy Outs" should not be available to the general public. They a made from tool steel (harder than typical bolts), they are not designed for seized bolts, but broken bolts. An engineering shop with a desintegrator (EDM) is what you need now.

I have easy outs from when I started my apprenticeship as a Fitter and Machinist in 1981. I was told back then: use with extreme caution!

It may be cheaper to buy another caliper/s (I may be able to supply).