Stuck M16 pop-in connector

John53204 · Post by **John53204** » Fri Jun 30, 2023 1:53 pm

Greetings,

I've recently acquired a doll that has an m16 pop-in connector broken off in the neck, and need help removing the bolt.

The pop-in bolt was built into the head, and snapped off in the body. These bolts are usually just pulled out, but as it broke in an uneven nub, I cannot get a grip on it anywhere to pull it out. Tried pliers, vice grips, adjustable wrenches, screwdrivers between the bolt and the receiver tube.

Tried to drill into the bolt to even out the nub or make something to grab, but I can't clamp down the doll down, and the movement makes drilling tough.

Sorry for the dirty pictures. They were taken after I'd been working at it for a bit. Can post cleaner pics if it helps.

Any suggestions? Please and thank you!

Space1invader · Post by **Space1invader** » Fri Jun 30, 2023 2:11 pm

Ooooo.... you need the specialist...

Starquake · Post by **Starquake** » Fri Jun 30, 2023 4:54 pm

I would try to cut a groove in the top of the nut with a dremel tool so you can unscrew it with a screwdriver, if you can

JRG · Post by **JRG** » Fri Jun 30, 2023 5:04 pm

Get an easy out bolt extractor. It should get enough grip to use vice grips to pull it out, or slowly loosen it with a drill. I’ve never used one on this type of fastener, but it should work. Additionally, don’t crank up the torque on the drill too much.

Wheezer · Post by **Wheezer** » Fri Jun 30, 2023 5:49 pm

John53204 wrote: ↑Fri Jun 30, 2023 1:53 pm Greetings,
I've recently acquired a doll that has an m16 pop-in connector broken off in the neck, and need help removing the bolt.
Any suggestions? Please and thank you!

If the connector did not "pop out" and rather "popped", then obviously there is a serious problem.
Rust, corrosion or just plain crud must have locked it in place, otherwise it would just easily spin when you try to drill it.

If it were me, I would try a screw extractor and then penetrating oil.

First slowly drill in and insert an extractor so it gets a good grip.
If there is a problem with the bolt spinning a bit during drilling, then jam in one or two small small flat blade screw drivers to lock the bolt in place.
Use care when inserting the extractor. The bolt may be "stainless" and a bit tough. You don't want to snap off the extractor and compound the problem.

Then add penetrating oil to the bolt perimeter, wait and see if it rotates better. If not do more and wait more and repeat.
Once it moves repeat the oil, wait and spin until it moves easily. Wiggle it a bit while spinning to try and free up the compression spring.
Then try to wiggle it out puling up.

Pop in connecters usually have one or two ball detents that have a compressed spring to supply force to prevent removal and rotation.
If that gets "gunky" the spring will not compress and can lock the connector in place. Or the ball(s) may have frozen to the body tube.
If it rotates a bit then the ball is rolling, but the spring is not compressing.

Either way, the oil and rotation should break them free and allow you to remove the stud.

Cheers!
... W ...

SAMPLE SCREW EXTRACTORS

: 61o11ldBdGL._AC_SL1500_.jpg (97.92 KiB) Viewed 234 times

: 61gp+upu7vL._SL1500_.jpg (123.84 KiB) Viewed 234 times

: 71EA6-b7+cL._AC_SL1500_.jpg (247.39 KiB) Viewed 234 times

John53204 · Post by **John53204** » Fri Jun 30, 2023 7:04 pm

Thanks for the response. I picked up an extractor set, but because of that metal nub, I can't get an extractor anywhere near the center of the bolt. I tried drilling at the nub, but didn't make much progress on removing it.

Can I remove that metal bit to create a place to use the extractor?

Wheezer · Post by **Wheezer** » Fri Jun 30, 2023 7:31 pm

If you have a Dremel, small grinder or whatever then you can work on making a sort of flat spot to assist in drilling.
Flatten as you see fit, center punch a good starting hole, then work up to a decent sized hole using several sized bits.

If your existing hole is off center, then center punch on the away side and try to center the existing hole. Or grind a bit to try to get the hole back near center.
There are MANY old machinist tricks to recover from an off center hole, and I'm sure there are some old machinists here that can assist with their preferred tricks. Or just dig a bit on the internet.

All you are really trying to do is get the extractor into the bolt to manipulate it and assist in getting it out. Sort of adding a handle to it to make manipulation easier.

Make sense?
Cheers!
... W ...

seagull · Post by **seagull** » Fri Jun 30, 2023 7:51 pm

Old machinist here, what Wheezer said and use a small Cobalt drill fairly slow rather than HSS, then once a hole is established, open it up to the largest that an extractor can be safely used in.
Fingers crossed for you John