We just acquired a VW diesel rabbit for $400. The intake manifold
fell off after all four of its mounting bolts broke.
One of these broke off sufficiently above the machined side of the
head that we were able to turn it out by striking the burr with a
However, the other three are broken slightly beneath the surface.
Ideally, we'd like to remove these without having to remove the
Indian .. er.. engine...
I am wondering about the possibility of striking an arc on the end of
each bolt and building this up until it's above the surface and then
turning 'em out with a chisel as we did the first one.
Some time ago I read about a trick like this where the guy strick the
arc inside a small piece of copper tubing placed into the hole.
However, I presume that in his case he was working with a steel bolt
inside a steel head and that the purpose of the copper tubing was to
keep from welding the stud to the head.
So the plan is to use some reasonably small rod at a suitably low
amperage WITHOUT the copper tubing. As I perceive things the aluminum
will not melt because it is a better conductor of heat than the steel.
However, in my mind everything is easy. It's at the "reality
interface" that things start to go wrong.
So, is this a viable plan? And if so, what rod flavor and diameter
would YOU recommend.
All answers appreciated. Correct answers REALLY appreciated. Plan
"b" is to remove the engine and drill 'em out.
There is just enough room between the work area and the firewall to
make this doable if I bend the rod into an "L" shape.