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M_V
While I was touring in morocco; a stainless rack bolt sheered in my fork, with the weight of the front panniers, riding on rough gravel roads. I managed to bodge the rack back on, using the lower braze-ons,to finish the trip, but it ended up sitting a couple of inches higher than it was supposed to.
First tried extracting the bolt with a set of snap-on extractors, but it was loc-tited in, and the sheered face wasn't flat enough to drill a central pilot hole. Resorted to drilling it out to 5mm, using an extra long bit. Drilled out the other side first, the went in to the sheered bolt from the inside. As it didn't come right to the end of the thread it was guaranteed to stay nicely centred, and minimise the risk off trashing the fork. Worked a treat, and now I'm going to use a pair of longer A4 bolts with nyloc nuts in the inside, which will make them super easy to repair if the sane thing happens again, in the future.