I've had a bit of a disappointing day.

This morning I met a club member who helped (well, he did it all) weld the patch on the bottom of my grill. I was real happy until I got home and put the insert in. It's off just a bit. :? So now what? I wish I had remembered the insert, not that it would have made much difference. Anyway, I guess I'm going to have to ask him, and show him what's wrong. Luckily, I have a second patch if needed. But that one is fabricated, and not cut from a junk grill like this one is.

My second disappointment is in myself. I was pulling the manifold mounting studs out so I can clean them up. (Turns out a couple are longer? Is that supposed to be like that?) When I replaced my water jacket cover 2 years ago, one of the nuts was seized on the stud and broke it off. So, since I was pulling studs I decided to pull a good one and see if I could replace the missing one, rather than having another bolt there. Stupid decision. I snapped that one off too. Now I have to drill and retap that stud.

Those water jacket studs aren't welded in there, are they? If not, I'm going to get two replacements... after I successfully drill out the remenants of the old one.

*sigh*

With insert in hand, a welder will fix it (no issue).
Studs are like sleeping Ogres, leave them alone unless they are already dead.
Drilling is OK be careful to be exactly centered, and drill in 3 stages each bigger, until there is just a rim of material left in place. Look at it a lot to assure you are centered when the last drill is used. Then use a next size drill In 64ths of an inch! to just nick into the base of the threads. Heat it up with a propane torch (as hot as it will get, aiming into the hole to super heat the remaining thread coil, then let it cool and use a dental pick to unwind the spring like thread. JimN

Back in the day it seems I was alway drilling out manifold and exhaust studs on my current hot rod. We always thought we could make a better exhaust than Detroit. There is nothing I can add to Jim's advice except that before I use the last size drill I would give a good ez out a final try.
You might get lucky.
I don't know who makes them but I found an ez out that has very sharp edges and bites a lot better than the ones I had years ago.
Dell

Keep temperment in check when removing broken bolts.Scott

I'll expand a bit on Jim's answer.

When drilling out a small stud, The center may not be where you think it is. One side of the broken stud might be a full thread and the other side might be the root of the thread. So you need to study it before you strike it with a center punch.

If you can find a reamer index at a flea market, you would be better off using the reamers for the finishing cuts near the wall of the stud. Reamers are good for .015 to .020 per cut.

You also have to be careful to drill straight. You can probably handle one axis but you might want someone else to sight the other axis as you drill.

Plan B is a fall back solution. That means you screwed up everything. In that case, you will have to drill and tap for Helicoils or similar insert.

mike, mike, mike, always measure twice and weld once!!!!!!! you need the grille insert to set up the position to weld the patch in. is the used piece in crooked? you may need to do a little metal work with a hammer and dolley to massage it for a better fit. if not, do you still have the insert i made for you ? you may need to remove the bad one and then weld in the replacement, however, be sure to fit it first. now if you would transfer to a navy base near yorkville, i could weld it up for you!!!! with all the rain we been having here, i think i saw a submarine in the headlands on my cornfield this morning!!!!

Hey Mike,

Can you post a picture of the insert fitment problem? I have a feeling that a little work with a file is all you'll need to get it fitting properly.

Did you get the wiring and the radiator installed?

To answer your ? re the length of the manifold studs, look closely at your manifold. If it has two different thicknesses of the flange then those thicker portions need longer studs. I think there were different lengths on my H but it's been sold so I can't check that. Also be aware that there should be extra thick "manifold washers" on the flange where there are expansion slots.
Cobaly drills the only way to go on drilling, or comshaw some carbides from a machinist on the base. Return them of cvourse when finished.

Gordo

Did you get the wiring and the radiator installed?

Click to expand...

Radiator is waiting for the new drain pipe. Wiring is waiting for some parts to come in. All in the works.

Can you post a picture of the insert fitment problem?

Click to expand...

I can. It'snot off by much, but enough to tell. I'll snap a photo and post it later.

Wardner does not state it strong enough. There will always be the root of a thread on one side and the full thread on the other side of an evenly broken bolt so the tendancy is to punch the middle of what you see instead of the middle of the bolt.

i have had some luck with broken stud or bolt removal by welding a oversized nut to the stud . even if its broke off flush sometimes this works. i use a mig welder or arc with a small rod. if it sticks good and you wait for it to cool some they generally turn right out . i think the heat helps. this may not be an option if youre not a fairly good welder and if your having someone else weld on your grill it doesnt sound like you weld. i think welding a nut on is a whole lot easier than drillin any day! my $.02 worth