Got that broken starter bolt out today! Took a bigger and better bit and some thread cutting oil. Found some that foams up so I could spray it upside down! Got a good pilot hole and the extractor got it right out.

What I noticed when I got the bolt piece out, is that it appears to be just a hair too long. I think it bottomed out in the block before getting the starter 100% snug. The very bottom of the bolt looks a bit worn and it is shinier than the insides. Hope I can find some shorter ones. The new starter I ordered will be here tomorrow so I'll pay extra attention to the length of the provided bolts.

You might want to check all the inside of the threads and make sure their is no grease or dirt at the bottom of the holes, kinda the same thing happend to me on different hole I had a mud dobber build a nest inside the hole and I was trying to get a bolt in it and would only go in half way in till I took the bolt out and discovered the mud inside the hole:clonk:I am just glad I did not try and tighten it down and break it off inside the block, that would have sucked big time..

that's about the quickest way to break off a bolt. You might consider running a tap or thread chaser in there.

About blind holes, and learning the hard way, about 45 years ago I had this street rod with an unobtainable top shift Ford trans, did not have a pump for gear lube so I put the trans in the car without the top cover and poured the oil in the top, then installed the cover. Indoing so I spilled oil into one of the bolt holes, screwed the bolt in and split the transmission case in half!

Got the starter back in, tried to fire it up but not enough juice left in the battery. She hasn't been run in a while.

The starter engages about 1/2 of the time, the rest of the time it just free wheels. I am assuming I need to shim it closer.

sounds more like a problem with the Bendix/starter drive to me. the starter doesn't move around from one time to the next.

Hmm, thought I replied to your post already...

I got under the car and had the wife bump the starter a few times, and it is definitely internal. Luckily the new starter came today and got it installed. New one works flawlessly and even sounds cooler. Got it fired up for the first time in around 3 months.