Rusted off manifold bolts

[SnoFarmer]

Rusted off manifold bolts.I've been wrestling with some badly rusted studs.2 out of 6 came right out2 were rusted off right at the head.I welded a nut to what was left of the stud and worked 2 more out this way.I drilled one out, that went ok but on the last one I rushed it and snapped off the bit in the hole. Have any of you used a torched to blow out the hole?It's getting close to snowplowing season, so I I'm looking for a quick fix or I'm going to bolt it back on with a gasket and fix it the right way in the spring?

[Mopar1973Man]

Rusted off manifold bolts.

I've been wrestling with some badly rusted studs.

2 out of 6 came right out

2 were rusted off right at the head.

I welded a nut to what was left of the stud and worked 2 more out this way.

Nice way of getting it out..

I drilled one out, that went ok but on the last one I rushed it and snapped off the bit in the hole.

Uh Oh! :eek:

Have any of you used a torched to blow out the hole?

No... I haven't. But I don't suugest trying to burn it out.

It's getting close to snowplowing season, so I I'm looking for a quick fix or

I'm going to bolt it back on with a gasket and fix it the right way in the spring?

Well the problem is cast iron doesn't take much for abuse like using a torch or such because its so brittle. But you mighyt be able to heat it up good enough to maybe soak WD-40 or similar in there and might break it loose using a small punch or chisel... Might even get the EZ out - out of the broken bolt... :confused:

[SnoFarmer]

Well It's snapped off about 1/4 in the hole. I cleaned up the threads(what I could get to) and put a bolt in it and snugged it up.I haven't had good night's sleep scene. This is my front line plow rig so I can't be messing around with her to much until spring. Then I'll get back in there and see if I can fix it right.

[Mopar1973Man]

Errr... Ummm... I know what your meaning the front line rig can't be down... At this point all I can say is try it with the broke bottom and see if you can get away with it... Just remeber that if it starts leaking exhaust you loose boost pressure.

[SnoFarmer]

Sorry, I didn't say what it is on.It's on a 01, 360 gasser.I put a gasket on it too.Stock they don't use a gasket any more.But I put one on it any way.

[Mopar1973Man]

Well hell that no biggy then... I would just dive into it and put the manifold on with a fresh gasket and call it good for now. A small exhaust leak on a gasser isn't a biggy... Annoying more that a hurt.

[guesswho512]

my buddy's 94 GMC 3/4ton with a 350 often vibrates the nuts loose on the manifold. the leak causes him to loose torque pretty quick, also mpg's a little

[keydl]

Lefthand drill bit and a close drill or adapter?Slip a bit off copper tube in to protect the threads that are there and build up weld to weld a nut onmake a guide to center the drill and drill through the broken piece, add penetrating oil at both ends and try the ezout aginWith a guide the bolt can sometimes be drilled and tapped, hard to hit that close freehandWhen all else fails a helicoil or a larger boltA carbide masonary bit can be sharpened to cut a drill or elrctro discharge machine will eat it out

[flman]

Take a stick welder to the bolt, and stick the rod to the broken bit, you should be able to reverse it out, you could even remove the bolts this way, if they weren't so rusted in.

[keydl]

Stick has a good chance of pulling the drill end, shield the threads with copper to keep the threads clear so the stub will thread out, some No-sieze on the end of the tube helps also.High temp RTV will glue it on, takes a day or 2 to cure above freezing as glue, the cure is water vapor asorbtion.

Edited January 12, 2010 by keydl