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HELP!! Broken bolt in head - Exhaust manifold

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kman View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote kman Quote  Post ReplyReply Direct Link To This Post Topic: HELP!! Broken bolt in head - Exhaust manifold
    Posted: June-11-2014 at 1:50am
7 out of 8 ain't bad unless number 8 is broken off in the head and then the easy out breaks off in the bolt... Imagine a grown man crying now. I have gone through all the bits at home depot, lowes, Fastenal & Northern Tool. I have a divet in the bolt and all the bits I buy just spin with NO bite. I got a left handed bit to bite for about 2 turns and then nothing. Please help!! Is there a magic drill bit somewhere? I'm drilling slow with lubrication. Been two weeks of off and on trying as I watch June coast on by...
Kirk

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JoeinNY View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote JoeinNY Quote  Post ReplyReply Direct Link To This Post Posted: June-11-2014 at 2:23am
7 will get the job done - if you cant live with that dremel in a slot and use an impact driven screwdriver. But seriously 7 will work...
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Post Options Post Options   Thanks (0) Thanks(0)   Quote TRBenj Quote  Post ReplyReply Direct Link To This Post Posted: June-11-2014 at 8:24am
Yeah, what joe said. Some aftermarket manifolds only use 1 bolt per cylinder.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote baitkiller Quote  Post ReplyReply Direct Link To This Post Posted: June-11-2014 at 9:05am
Got a welder? weld a nut on it.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote GottaSki Quote  Post ReplyReply Direct Link To This Post Posted: June-11-2014 at 11:05am
Another ditto what Joe sez
Next time skip the easy out, and go straight to the left handed bits.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mamigacz Quote  Post ReplyReply Direct Link To This Post Posted: June-11-2014 at 3:15pm
Originally posted by baitkiller baitkiller wrote:

Got a welder? weld a nut on it.



I've had success with this. Plus getting the head cherry red around the bolt with an acetylene torch before removing the bolt. Its possible that an oxy-MAPP torch might work too.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote JoeinNY Quote  Post ReplyReply Direct Link To This Post Posted: June-11-2014 at 3:34pm
Ive got a welder, but I am only a hack... I would weld in this scenario only as a last resort, and then only over the winter after I had skied all year on 7 bolts...    If it is a pcm engine then it was likely a hardened bolt and to get something welded to it with a chance of success would require enough heat that I might just weld that stud to the head then I would be cutting it off of a surface I want to be as flat as possible so I can seal against it with only one bolt.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote backfoot100 Quote  Post ReplyReply Direct Link To This Post Posted: June-11-2014 at 3:52pm
Another option is remove the head and find a shop that has an EDM extractor. They work wonders but not a lot of shops have them. Definitely need to call around first.
Unfortunately, removing/replacing the head is much more time consuming.
When people run down to the lake to see what's making that noise, you've succeeded.



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Post Options Post Options   Thanks (0) Thanks(0)   Quote 8122pbrainard Quote  Post ReplyReply Direct Link To This Post Posted: June-11-2014 at 9:43pm
You have work hardened an already hard bolt from bits skidding on the metal and not cutting. Carbide drill bit but be careful as they are brittle and with a hand drill you need to be very steady. If that and a easy out doesn't work then I agree with Eddie's suggestion of using an EDM. A very aggressive cutting angle on the bit is needed since with a hand drill you can't get much pressure on the bit. The only bad side to this is having to sharpen it frequently. Do you have a bench grinder? Also did you start off with a small diameter pilot hole. I can't tell from the picture. With a hand drill and the lack of pressure you can apply, with starting with a small diameter bit, you can apply more pressure at the bit. Then increase the bit size a couple times. What type of extractor are you using? I hate the tapered spiral ones. They will actually expand the bolt tightening it in it's threads. I like the spline type.


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