Manifold bolt Issue -Help!!!

[Guest]

In an attempt to change out a rusted and bad looking 2 into 2 turn out exhaust on a 1977 750b into a new vance and hines 4 into 1 exhaust, I have screwed up. 7 out of 8 manifold bolts came out just fine. One of the bolts was seized and broke off. I drilled out the bolt (1/3 of inch) and tried to use a screw out tool to take out the bolt. The screw out bit broke and now I have a seized manifold bolt with a portion of a screw out tool jammed into the bolt. Anybody have any suggestion for the next step?

[Big T]

Take a pin punch and see if you can knock that broken off EZ Out from the hole. It's too hard to drill

Then go back and drill some more with ever larger bits, with very slow revs

Don't drill too deep (use another hole to make a gauge)

Worse case, you have to pull the head and take it to a machine shop

[sedelen]

What a bummer.
I'd really like to see a picture of what you're up against.
But with the information you told us,
If there is room between the EZ out and the width of the original screw/bolt (that broke off) threads, I'd be tempted to drill small holes around the outside of the EZ out as close together as I could, then maybe the next larger bit size to
break down that wall between the small screw holes. I would think then you could knock that EZ out loose with a pin punch (but don't break the punch in the holes!).
Lots of light, lots of patience, really sharp bit, and cool tool or something to cool and lubricate that bit.
I don't think I'd go any deeper than the distance you think the EZ out goes into the broken bolt.
Should this work it would at least put you back to where you started.

[Grey Beard]

Thank you for your suggestions,
I will see tonight if I have room to drill a couple of small holes to around the broken screw out. The screw out is jammed pretty good and I have not been able to jar it loose with just a pin punch.
I let you know how it goes.

[Agemax]

dont forget you need to be tapping the broken EZ out in a clockwise direction to loosen it.
just in case you didn't know that already...............

[sedelen]

Yours is but one of many that have been through this.
You can go through these threads and maybe it'll give you other ideas.

http://www.thegsresources.com/_forum/search.php?searchid=3337785

[chuck hahn]

sometimes..since the EZ out is a left turn tool, a drill bit will loosen its grip off the stud. Use an old crappy bit and chatter then helll ouit of the broken EZ out and see if it loosens its grip. Then a little pick may be able to get it wiggling out of the pilot hole.

If it comes out, do as was suggested by marking your drill bits so you dont drill too deep and hit an oil galley in the head. And you can stick a dowel to the bottom of one thats out and use that depth as a guage..stoppping about 3/16 short of the bottom of the hole.

Next drill all the way thru the stud slowly and easily. Step up to the next size and so on till most of the studs center is removed. Now you can collapse the sides of the stud into itself and use needle nosed pliers to twist and remove it. Some heat and oil will aid in getting the core to move.

[Grey Beard]

After many attempts drilling, knocking and just plain old verbally pleading (cursing) the easy out bit will not release its grip on the manifold bolt.

As such I have taken the issue up with the King, and the verdict is .......

"OFF TO ITS HEAD!"