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 chisel.
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.