can't get penetration on broken bolt

3.5 inch drive · 2009-08-22T01:40:25+00:00

I haven't posted to this group in a couple years, but now I'm stuck.I'm trying to remove a broken exhaust bolt from a cast iron engineblock (LT1). The engine is on a stand, the exhaust manifold is off,and the bolt sticks out about 1/4 inch. There were a couple otherbroken bolts that I was able to remove with a torch and stud remover.But this bolt is too short for my stud remover, so I've been trying toweld a nut onto the end of it. The problem is that I don't getpenetration into the end of the bolt, so when I put a wrench on thenut, it just twists off. I have tried this five or six times, andhave temporarily run out of nuts. I'm using a mig welder.Any suggestions? I'm thinking of grinding down a nut to be thinenough so the bolt sticks through it, so there's more bolt exposed toweld to. Vise grips didn't work. If I could find a low-profile studremover I think that would work. This is for a simple engine swap, soI want to avoid pulling the head to take to a machine shop.The one thing I'm not going to do is use an easy-out. I've never usedone successfully.Dave Wilson

Aug 22, 2009 23 Replies

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Gunner Asch 17 years ago

My R90/6 BMW scooter was left for years on the kickstand. One cylinder froze. I tried a bunch of stuff to free it up. Nothing worked.

I sprayed ((out of desperation) the cylinder full of PBlaster and went to dinner. I came back out 5 hours later, and it kicked over like Id just shut it off after a run.

Good! s*it, Maynard.

Gunner

Whenever a Liberal utters the term "Common Sense approach"....grab your wallet, your ass, and your guns because the sombitch is about to do something damned nasty to all three of them.

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