Broken Bolt bound too happen eventually

[Cyg]

While takeing off the headers, using lots of pb blaster. I have one broken bolt in the head.. Now the options I know are helicoil, heat, vice grips. Its an alluminum block. gs 1100 84. shaftie. I want too put on my vance and hines on her they came in this week.

So any other ideas on how too remove this obstacle from my presence.?

[GSstiny]

Ah. Thats an easy one. If you have to break a bolt off thats the way you want it to happen. Id try the vicegrips. You never know. If that doesnt work Id weld a nut to it, that should bring it out.

[Cyg]

now weld a nut that is agood idea. ill try that instead the heat would loosen it up too as i weld.

good idea. thanks

[frosty5011]

Looks like you might even have enough thread left on that to put two nuts, counter-tightened against each other, on it (if you haven't already messed up the threads royally with vice-grips).

If that's the case, tap the end of that baby with a hammer for a while and melt some paraffin on the threads.....then put on the nuts and see if you can't screw it out.

[jimcor]

If that's the case, tap the end of that baby with a hammer for a while and melt some paraffin on the threads.....then put on the nuts and see if you can't screw it out.

You have no idea how important using a hammer to pound on that broken bolt is. TAKE YOUR TME. A couple of days. Spray with PB. Pound on that bolt. Leave it sit. Pound on it some more, Spray again. Pound. Spray. Pound. Spray. Take a couple of days. Then put a vice grip on it and it will probably turn right out. The paraffin is a time tested fix also I've just never used it. Remember, TAKE YOUR TIME and do it the easy way. Or get in a hurry and end up having to pull the head and have that baby burnt out.

Wingnut, who is a member of this group and an aircraft technician, explained the importance of pounding on that bolt to me. I was able to remove 8 stuck bolts doing it this way.

[ghwrenchit]

now weld a nut that is agood idea. ill try that instead the heat would loosen it up too as i weld.

good idea. thanks

Welding a nut is a great idea!! Just had this exact thing happen on the wifes 550L X 1 bolt at each exhaust port,#-o... all broken flush with the head.... four frickin' bolts!!!

As stressed before "TAKE YOUR TIME".

I ended up cleaning up and grinding flat every broken bolt surface with a dremel. Carefully center punched each one, and carefully drilled thru each one with a long reach #21 drill.[-o<

Turns out that a cavity existed behind the end of the bolt and the head, which allowed the drill to pass all the way thru the broken bolt.

I soaked them for days with PB Blast, then tried the EasyOut, which broke off in the first bolt.

Ended up tapping the broken Easy Out piece all the way thru the bolt with a small punch, forcing the piece in the cavity "behind" the bolt.

Bought a 1/8" 4-Flute carbide cutter and ended up carefully "carving out" each bolt with the dremel / flexshaft until I was close to the aluminum head threads. The bolt pieces starting falling in, and the dremel did little damage to the aluminum threads. Need to do one more tonight, then re-chase the threads with a 8 X 1.25 tap.

Hopefully your project won't go to this extreme, but wanted to post the process I ended up with, as it finally worked out with patience.

GoodLuck...

ghwrenchit

[Cyg]

wow well this is going to be two threads one here and one too show my beautiful baby.

Ok here is what I ended up doing. and the credit goes too all of you. I just took what I needed from each and came up with this idea.

I welded a nut on but then it broke off closer too the block. So I said humph in not so many nice french words. I thought to myself I can weld a bolt on instead of a nut. I did bang on it soaked it all day in pb blaster etc. I thought too myself if I am carefull I can weld a stub on there and make the bolt bigger. That is exactly what I did. Then capped them off with two nuts

[nabrams]

That's a very cool solution. Many of us don't have welding equipment, so the for really bad situations we are forced into the drill/tap/heli-coil routine.