Best course of action--broken header bolts

[broncomania]

gotcha




Ok, but won't the two bolt holes i'm working on be different sizes than the other 6? Well, maybe not if i Helicoil them, but if i just drill/thread...

if you make the bolt hole larger , will a larger bolt fit through the header ????
probably helicoil them. i know this is a pita. good luck. :beer:

[johnpaulgolf]

OK here is another deal cratchhe:...put full coverage insurance on it... and then strap dynomite to itupergrin:...can you see where I'm going with this?.:hysterical:



:gunshot:

:rebel:


:banghead::banghead::banghead::banghead:

[bucketobolts]

I've had luck using my MIG welder to build up the bolt and spot weld a nut to it. The heat will help break it loose. Though this works really well for bolts that are above the surface. You have to be careful when they are below the surface, but it can be done with patients.

Do you have inner fenders or have they been removed?

[Ogeechee 4x4]

I've had luck using my MIG welder to build up the bolt and spot weld a nut to it. The heat will help break it loose. Though this works really well for bolts that are above the surface. You have to be careful when they are below the surface, but it can be done with patients.

Do you have inner fenders or have they been removed?

I do have the inner fenders, I just took them off to install the headers. They're not too much of a PITA to take off. Does give a lot more access :biggthumpup:

OK here is another deal cratchhe:...put full coverage insurance on it... and then strap dynomite to itupergrin:...can you see where I'm going with this?.:hysterical:


:banghead::banghead::banghead::banghead:

I know exactly what you mean! Everything i do to this POS backfires against me. It's like the bronco is fighting me at every turn.

[Ogeechee 4x4]

So a little update:

Spent the last 10 hours installing the two 3/8" helicoils. Yes, I work slow. I'm also bad about walking away from one project and starting another...I think I had about 4 going at one point today, haha.

The exhaust isn't 100% sealed, but it's pretty darn close. And it's a LOT quieter than it was. So I'm happy. I suppose I can change my sig now...

[manny]

I go for the extreme side for me normally what i handle is weld a nut to it.... The heat of the weld shrinks the bolt as it cools and it pops loose. Your best bet would be as stated go slow with carbide bits. Stick the bit in a hole that is clear and mark the bit of the depth of the hole. That way you don't go too deep and hit water in the blind hole. For the stripped hole retap it, and try a fresh bolt chances are you just pulled the threads on the bolt as old, and brittle as it was the threads in the head may still be goodcratchhe: you think jon......:banghead:

[Ogeechee 4x4]

i tried to weld another bolt onto the broken bolt, but

A) i didnt have room to get the electrode and the 2nd bolt into the hole in the block

B) it took me 4 times to figure out that the vise-grips i was holding bolt #2 with were conducting the welder's electricity and that's why my arm was twitching


I've successfully done this trick in the past, when i had more room to work with....

[gulfcrestinc]

do you know anybody with a heli-arc machine. if so just build up enough to grab it with the visegrips and turn out. the bad thing is that by weldin on the bolt your makin it hard so drill it out takes on a new level of fun. use a 680 wire if tiggin it out. that the best for doinin that. it can be done with a er70 wire if you have to

[lobo1117]

Use a cobolt drill bit, carbide is too brittle and will chip the flutes.. cobolt is what is used to drill stainless steel.. get at any industrial supply or MaMaster-Carr http://www.mcmaster.com
And its a whole lot cheaper than solid carbide..

[chuzie]

WOW! I never heard that. Makes sense though.