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Broken Head bolt on DC

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L.Lamp

02-09-2008 19:48:22




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I broke a head bolt trying to straighten it up to get the head gasket to fit over all of them. Worse, I also broke an easy out off in the hole I drilled through the broken bolt. What can I do to get the bolt out and still save the threads in the block??




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dboll

02-11-2008 11:28:06




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 Re: Broken Head bolt on DC in reply to L.Lamp, 02-09-2008 19:48:22  
I can count on one hand the bolts I have removed with an ez out, go with Mel's idea, I have gotten out many that way, last resort, torch it out ,if careful you won't damage the block threads



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Allan from PA

02-10-2008 08:11:14




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 Re: Broken Head bolt on DC in reply to L.Lamp, 02-09-2008 19:48:22  
Bruce has the right idea if you do not have the option to or do not want to apply any heat to the block. If the stud is bottomed out in the hole or very rusted in the hole they can be very stubborn to remove because they are a tight thread to start with. I just removed two studs that I broke off flush with the block on my recently purchased 1941 SC block. I used a .125 ball carbide burr to go straight down as close to the center of the hole as possible. Carbide is used because it is hard enough to cut the extractor as well as the bolt. Once the center is established work the hole just large enough to get the burr to go down a small amount then work the hole to the previous size and then continue on, further down. The object I am trying to do is to grind away the extractor and then the bolt to such a thin wall that you can see the threads of the block starting to show through the bolt. You can then start to pick away at the threads with a dental pick. After you are satisfied the wall is thin enough and enough of the threads are exposed then you can VERY carefully start and run a tap through the hole using anti-sieze compound as a lubricant. Some things that help a lot doing this this way is a small high speed die grinder, a lighted magnifier lamp and most of all patience. It may take a few burrs and a couple hours a hole but when done you will have a good threaded hole that will still hold torque.

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mEl

02-10-2008 05:36:04




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 Re: Broken Head bolt on DC in reply to L.Lamp, 02-09-2008 19:48:22  
cover everything and get a big flat washer , use good heat setting and weld it to the broken stud, weld a nut to the washer, allow to cool and see if you can get it started loose, use a good penetrant and tap to work it in, i have used this method even when studs where broken off below flush by building the stud up flush and then doing the washer thing. I did this to about 6-8 studs on a DC block and saved all the holes, but had to weld several washers and nuts on a couple, if your easy out is straight down the stud it will not bother anything, There is nothing up on top to keep you from heating the washer and stud up real cherry red to shrink the stud to release it in the threads before welding the nut on, sounds extreme but broken studs are a problem for all of us, hope this works for you, mEl

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Bruce Nelson

02-10-2008 05:27:55




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 Re: Broken Head bolt on DC in reply to L.Lamp, 02-09-2008 19:48:22  
Larry, you can fix this. Here is what I do. Get a carbide burr on a die grinder and grind into the EZ out. I would use a 1/4" or 5/16" round ball burr. Be careful to grind the hole a little bit larger than the carbide burr, or the burr will catch on the sides of the hole and snap right off of the shaft. Keep the bit cool, dunk it constantly into some WD-40 or diesel fuel. Slowly you will be able to grind deeper and deeper into the EZ out. Once you get deep enough to where the diameter of the tapered EZ out is reduced enough, (not much larger than the hole you drilled), you can drive the EZ out through the headstud (if you drilled the original hole all the way through) into the water jacket of the block, where it can stay. If you did not drill all the way through the stud originally, you will have to remove more of the EZ out by grinding, till it gets small enough to come out the top of the hole. Bruce

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