Broken Bolt Removal Tip - Team Camaro Tech
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post #1 of 14 (permalink) Old Dec 18th, 12, 05:23 PM Thread Starter
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Broken Bolt Removal Tip

I had three exhaust manifold bolts snapped flush with the heads on the LS I picked up. I tried Easyouts, which didn't work. Someone had suggested welding a nut to the end of the boolt, but I couldn't get a good weld down in the hole after several tries, so the nuts didn't hold.

Instead, I welded a washer to the end of the bolt, and then welded a bolt to the washer. The broken bolts turned out effortlessly. This was made easier since the heads are aluminum, which prevented the washer from bonding to the head, but a thin layer of grease on the bottom of the washer could probably solve that concern on a cast iron head.

Unfortunately, I forgot to take pics, but I think you get the idea.
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post #2 of 14 (permalink) Old Dec 18th, 12, 05:32 PM
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Cool Re: Broken Bolt Removal Tip

The combination of localized heat on the fastener and the increased perch of a nut really makes removing broken-off or frozen fasteners much easier

If you trying to get a bolt out without welding, the use of a "Left-handed" drill bit will yield great results.
I bet 90% of the time the piece starts to back out on the drill bit before it ever hits the bottom for me

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post #3 of 14 (permalink) Old Dec 18th, 12, 06:54 PM
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Re: Broken Bolt Removal Tip

So no new heads for you.

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post #4 of 14 (permalink) Old Dec 18th, 12, 07:23 PM Thread Starter
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Re: Broken Bolt Removal Tip

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Originally Posted by Vega$69 View Post
So no new heads for you.
Nope- was a bit saddened about that myself, but in the end, I'll still get the hp I'm looking for even without them, and will have about $1,500 to spend on the rest of the project.
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post #5 of 14 (permalink) Old Dec 18th, 12, 07:42 PM
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Nope ...
... and will have about $1,500 to spend on the rest of the project.
You'll burn through that in a heartbeat with just mounts, exhaust and driveline mods

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post #6 of 14 (permalink) Old Dec 19th, 12, 02:02 AM Thread Starter
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Re: Broken Bolt Removal Tip

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You'll burn through that in a heartbeat with just mounts, exhaust and driveline mods
Already accounted for that....
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post #7 of 14 (permalink) Old Dec 19th, 12, 07:12 AM
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Re: Broken Bolt Removal Tip

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Nope- was a bit saddened about that myself, but in the end, I'll still get the hp I'm looking for even without them, and will have about $1,500 to spend on the rest of the project.
I got a guy that will do a great mild port and polish for a very good price.

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post #8 of 14 (permalink) Old Apr 21st, 13, 06:49 PM
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Re: Broken Bolt Removal Tip

Nice tip! I've been welding nuts on forever. I've usually pulled it off with a small stick welder instead of the wire welder. This tip should make it even easier.
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post #9 of 14 (permalink) Old Aug 4th, 13, 04:35 AM
igra
 
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Re: Broken Bolt Removal Tip

sorry for my english a bolt means a hexagonal nut right,if so i saw a mechanic when a bolt was broken from both ends he hmm used a scratcher make its shape identical to a nut then very carefully opened it.hope it adds a new idea in your heads.

thanks for reading


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post #10 of 14 (permalink) Old Aug 4th, 13, 08:18 AM
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Re: Broken Bolt Removal Tip

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Originally Posted by igrapablov View Post
sorry for my english a bolt means a hexagonal nut right,if so i saw a mechanic when a bolt was broken from both ends he hmm used a scratcher make its shape identical to a nut then very carefully opened it.hope it adds a new idea in your heads.

thanks for reading
Filing the bolt end into a hex head could work. If you can get to it. You can also cut across with a hacksaw to make a slot for a screwdriver. Both methods require a bolt to be sticking up from the metal. Not very likely for most bolts.

Still, one more way to get a broken bolt out.
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post #11 of 14 (permalink) Old Aug 6th, 13, 10:12 AM
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Re: Broken Bolt Removal Tip

I just went through this yesterday on my 1998 Dakota p/u. Two ex bolts were broken, about 1/8" in the hole and really tough to access with a mig welder. I contemplated trying it anyway, but was afraid I'd just weld the stud to the cast iron head. Long story short, KROIL,left handed drill bits and easy-outs didn't work. Ended up drilling them completely, and retapped the holes to 3/8-16 and used grade 8 studs. They were originally wimpy 8mmx1.5.


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post #12 of 14 (permalink) Old Aug 6th, 13, 10:14 AM
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Re: Broken Bolt Removal Tip

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Originally Posted by BPOS View Post
I just went through this yesterday on my 1998 Dakota p/u. Two ex bolts were broken, about 1/8" in the hole and really tough to access with a mig welder. I contemplated trying it anyway, but was afraid I'd just weld the stud to the cast iron head. Long story short, KROIL,left handed drill bits and easy-outs didn't work. Ended up drilling them completely, and retapped the holes to 3/8-16 and used grade 8 studs. They were originally wimpy 8mmx1.5.
Yeah, times like that a 1/16 stick welder is handy. The flux helps keep you from welding to the sides as you get yourself started. As long as the bigger studs fit through the head you're probably better off now.
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post #13 of 14 (permalink) Old Aug 6th, 13, 10:25 AM
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Re: Broken Bolt Removal Tip

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Originally Posted by PatDTN View Post
Yeah, times like that a 1/16 stick welder is handy. The flux helps keep you from welding to the sides as you get yourself started. As long as the bigger studs fit through the head you're probably better off now.
I did have to enlarge the holes in the ex manifold, but cast iron drills like butter.

If I was smart, I'da drilled the others and done the same, but I'm not smart. The 3/8 studs are much bigger than the 8mm bolts I replaced.


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post #14 of 14 (permalink) Old Aug 6th, 13, 10:28 AM
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Re: Broken Bolt Removal Tip

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Originally Posted by BPOS View Post
I did have to enlarge the holes in the ex manifold, but cast iron drills like butter.

If I was smart, I'da drilled the others and done the same, but I'm not smart. The 3/8 studs are much bigger than the 8mm bolts I replaced.
LOL! Somewhere in the middle of my reply I started thinking you had replaced a head bolt not an exhaust manifold bolt. D'Oh!
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