Hey guys, During my desmog, I found a broken bolt and snapped another bolt from the intake manifold to the head. I tried everything; drilling it out, drilling with left turn drill bits, putting a bolt extractor in, etc... Now the bolt extractor broke off in the drilled hole. I have a 220v welder, cheapy from harbor freight, and I tried to weld a nut to the broken off bolt but the nut just pops right off. The broken extractor is hardened steel so I do not know if thats why the weld will not take. Also, I tried to re-drill the extractor but my bits wont work on that steel. Anyone have a similar problem?

.

 

dremel with diamond bit, lots of time and hope it works

 

Yep, dremel it if possible. You need a small carving type bit, Ive used the grout removal bit with great success as they are carbide treated.

You hit rock bottom when the bolt extractor broke off, its harder than the bolt.

Next time, heat and melt a candle over the threads. Will usually come right out. If you cant dremel it buy better drill bits and use LOTS of cutting oil.

 

Wow, I did the same thing with my thermostat housing two nights ago. I got one out with two nuts, but the other broke flush with the block. My bolt extractor broke flush too. I knocked a few chips out with a punch, but the rest is stuck.

 

Go in a time machine back 10 years an anti-seize everything.

 

I've got a similar problem. Two bolts broke off in the front of the block. One is the large one toward the passenger side in the middle of the water pump that goes into a dowel pin, the other was above it in the timing cover. The strictly timing cover one has enough thread sticking out I should be able to twist it out (hopefully). The one into the dowel pin broke the end off inside it. I'm trying to figure out how to get them out.

 

Okay I got it out. The dremel bits did not work for me. I bought some Bosch multipurpose bits at home depot. I broke 2 of them and ground the crap out of a 3rd. The bits wondered a little bit opening the hole bigger than normal. But once I got past that hardened steel extractor, By the grace of God,I drilled right into the existing hole. I simply drilled it a little deeper, but carefully so I didn't drill into the air chamber. Since I am putting a water block plate here, I re-tapped it enough to get a good grip on that bolt. Thank you for all the help, this is a great forum.

 

I have never heard of the dremel bit idea. I may have to try this on one of my many broken bolts to get out.

 

I picked up a grout removal bit this morning, so when I get tired of working at other things, I can grind away.

 

i've had success with breaking a broken bolt extractor with a hammer and punch. it is hardened steel but its brittle

 

ooh, I'll have to remember that one. I would have thought the pressure around the extractor would absorb the shock and prevent fracture... but hey what's a few minutes with a hammer and punch to give it a try...

 

I highly, and frequently recommend Kroil. It has saved my bacon on more than one occasion. I work on 40 year old tractors and rarely break bolts.

 

That grout removal but did the trick, now I'm back to getting the bolt out. I don't want to use it for the bolt because it might be too aggressive. I'm probably going to have to drill and tap it to the next size anyway.

 

Drill the hole in bolt slightly larger and put the next sized bolt extractor in there. It should work. The heat from drilling and the thinner metal in the bolt should get it out

 

So I finally got back around to working on this and broke a drill bit in it this time. I bought a new, nicer intake.