Author Topic: Bolt Removal Tech NEEDED! (Read 3702 times)

CTENG in KS · « **on:** Jun 30, 2007, 06:40:01 PM »

I am replacing the exhaust manifold gaskets on the big 460 in the SS Beastmaster and two of the bolt heads have broken off leaving about an inch of bolt thread sticking out of the head. Anyone have any great ideas as to how to get these out without destroying anything. Let me remind you that they are in a van so they are not really very accessible.

Please help...

79coyotefrg · « **Reply #1 on:** Jun 30, 2007, 06:42:05 PM »

can you geta small torch to the area??

UGLYTOY · « **Reply #2 on:** Jun 30, 2007, 06:53:53 PM »

i have read in one of those beginner's welding books (had a blue cover...haynes?) about an attachment for a mig-welder that an exhaust shop uses to weld a stud where the old one was. they had a pic and if i remember correctly, it looked like they ground it flush, then welded this stud on. i think it may have been hollow and the mig wire went through it? basically, i'm saying call a few machine shops, exhaust shops, etc and see if they can do something like that before u get too frustrated. sorry i can't remember the name of the attachment.
if no one has it, u can try the torch method like listed above, just obviously don't get cherry red so u save the head, then try putting some wax on it because that is supposed to wick down in the threads and help ease it out. when that doesn't work, u may be pulling the head off. i'd call around first. u may have to let them cut the inner fenders a bit for access, but it'd be worth it

79coyotefrg · « **Reply #3 on:** Jun 30, 2007, 06:56:04 PM »

Tallchevy · « **Reply #4 on:** Jun 30, 2007, 07:32:19 PM »

We just went through this. I know it's a different engine but the removal procedures are the same

http://board.marlincrawler.com/index.php?topic=34708.0

CTENG in KS · « **Reply #5 on:** Jun 30, 2007, 07:39:03 PM »

OK, here are the issues...can't pull the heads off..
Can't get anywhere near them with a drill.
I will try to heat em up with propane torch, but that is all I have for heat.

79coyotefrg · « **Reply #6 on:** Jun 30, 2007, 07:43:51 PM »

that should work, then use a small pipe wrench to try and grip the bolt with and remove it Hopefully

Tallchevy · « **Reply #7 on:** Jun 30, 2007, 08:01:52 PM »

Can't get a angle head drill in there either? What is in the way, the inner fender?

79coyotefrg · « **Reply #8 on:** Jun 30, 2007, 08:07:14 PM »

Quote from: Tallchevy350 on Jun 30, 2007, 08:01:52 PM

Can't get a angle head drill in there either? What is in the way, the inner fender?

its in a large ford van i think theres about a inch of room

CTENG in KS · « **Reply #9 on:** Jun 30, 2007, 08:14:08 PM »

Quote from: 79coyotefrg on Jun 30, 2007, 08:07:14 PM

its in a large ford van i think theres about a inch of room

Winner...top of the engine is easy access...side...just forget it.

Tallchevy · « **Reply #10 on:** Jun 30, 2007, 08:18:27 PM »

What if you take the front tires off & go between the body & frame

CTENG in KS · « **Reply #11 on:** Jun 30, 2007, 08:45:44 PM »

Engine is too far back...these bolts are essentially under the dash.

fordh8r · « **Reply #12 on:** Jun 30, 2007, 08:56:09 PM »

One word of advise, if you don't already know, after you remove the broken bolt with whichever method you choose

, you'll also want to drill out both bolt holes at both ends (not the center holes) on those manifolds to the next larger size. The reason they shear off the bolts is from the expansion of the manifold when they get hot and the holes aren't large enough to take up the expansion (or sliding) without contacting the bolt and of course eventually causing the bolt to break. This is a common fix for that style manifold where the main body of the manifold is very linear to the mounting holes

. Just thought you might like to know.

85xcab · « **Reply #13 on:** Jun 30, 2007, 09:11:45 PM »

If you have a welder you can slide a nut on the remaining part of the stud and plug weld it to the stud. Gives you something to put a wrench on and the heat helps as well.
Maybe use a die to thread the inch of stud that is left(use a wrench to run the die because of space). Then put two nuts on the stud, tighten them against each other, put some heat on the bolt with a small torch and back the stud out with a wrench.

CTENG in KS · « **Reply #14 on:** Jul 01, 2007, 05:41:23 PM »

I finally got the bolts whose heads popped off out, but I can't get the ones that are rounded out...thining may dremel with the flexy thingy to cut off the bolt heads, then remove the manifold and do like I did with the other ones...

Old trucks are a pain.

Yota Up · « **Reply #15 on:** Jul 01, 2007, 07:39:53 PM »

What if you take a bigger, stronger bolt and weld it onto that rounded bolt, and then hit that with a long arm wrench?

85xcab · « **Reply #16 on:** Jul 01, 2007, 08:06:16 PM »

Craftsman and Matco both sell sockets to bite rounded bolt heads. I have a Craftsman set, they work good and fit in tight spaces.

CTENG in KS · « **Reply #17 on:** Jul 02, 2007, 06:00:33 AM »

Yeah, I have two sets...they bit and then just sheared the bolt down even farther. The outsides of these bolts are badly degraded and extremely soft.

CTENG in KS · « **Reply #18 on:** Jul 02, 2007, 08:38:06 PM »

This is the most frustrating thing I have ever done. I have one side free and clear. On the other side, now all those bolts popped their little bolt heads off and they don't wanna budge an inch.

On a related note...Dremel's suck.

That is all.

CTENG in KS · « **Reply #19 on:** Jul 03, 2007, 08:20:26 PM »

I tried welding a nut onto the bolt..worked great cept that it just broke the bolt off closer to the head. I think maybe I will just make a JBWeld gasket and run it like that.

Anyone have any other brilliant ideas? Any tricks? I don't have the time to be pulling this motor down for a manifold bolt.

Duffil · « **Reply #20 on:** Jul 03, 2007, 10:11:41 PM »

summitracing.com

CTENG in KS · « **Reply #21 on:** Jul 04, 2007, 06:04:22 AM »

uuuuhhhh, what does summit have to do with anything?

brainlessfool · « **Reply #22 on:** Jul 04, 2007, 06:51:07 AM »

90 angle drill with a short bit. I've had to drill exh. bolts ont on ford vans and know it not easy. but it can be done. drill all the way though and spray oil in it. then drill next size up and drill again. after it's about gone run a tap in it. should take about 2 hours per bolt and kill your back if your doing it right.

Tallchevy · « **Reply #23 on:** Jul 04, 2007, 09:31:54 AM »

Try to find a reverse drill bit so when your drilling it will back the bolt out too. I have had good luck with those

Duffil · « **Reply #24 on:** Jul 04, 2007, 10:54:58 AM »

Quote from: CTENG in KS on Jul 04, 2007, 06:04:22 AM

uuuuhhhh, what does summit have to do with anything?

I was just being a smartass, meaning you wouldn't have to worry about pulling the studs...

Tallchevy · « **Reply #25 on:** Jul 04, 2007, 11:03:16 AM »

can that F ix O r R epair D aily thing & get another rig

CTENG in KS · « **Reply #26 on:** Jul 04, 2007, 01:57:23 PM »

NO other rig will do...none can compare with the BEASTMASTER!

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