Broken Bolt Removal

[eLindemann]

So I got my new intake manifold bolts and decided to switch out the old with the new today. So I got my bolt extractors out to remove the two old, corroded, and stripped bolts. They both snapped right off. I'm not kidding.

Picked up a set of screw extractors at Home Depot and tried them out. BAM! Screw extractor snapped off in the broken bolt. Its as if those bolts have welded themselves in there. I managed to pry out the broken bit of screw extractor, but I'm still stuck with two broken intake bolts, and I fear that without all 12 being in I'm gonna have a leak somewhere and cause all sorts of problems.
A little more info, they snapped right where the thread begins, so the entire remaining bit of bolt is in the engine part. I've got my intake taken off and the bolts are almost flush with the engine.

So my question is: Anyone have an idea how to get these bolts out that doesn't require a screw extractor?

 

[elarm1]

oooooh That doesnt sound good. I can never get a extractor to work. That old screw will have to be drilled out. Or you can look for another set of heads. Where in N Va are you?

 

[rubydist]

here's how I would do that:
1. spray penetrating oil on the bolt each day for a week.
2. center punch the middle of the broken bolt.
3. drill the bolt w/ 1/8" drill. drill repeatedly with slightly larger drills until you are nearly at the size of the threaded hole. at some point along the way, the broken bolt should start to turn further in w/ the drill.
4. use screw extractor to take out the broken bolt.
repeat on other broken bolts.

 

[eLindemann]

Yeah. I kinda figured it'd be a really long and crappy process... I'll have to give that a try, as I'm sure I can't afford a new set of heads.

And elarm, I'm in a little town called Purcellville near Leesburg. So we're about an hour and a half away from each other.

 

[mattsho1993]

have you taken the intake off yet? if not take it off see if there is anything left to get a hold of use a little pb baster slight heat maybe if pb doesnt work and a stud extractor....

 

[SHOmethewayhome]

welder and a nut you dont care about FTW.

if you think the intake bolts suck, try the stud the MTX timing belt tensioner is on. I've snapped it twice now.

 

[lowc]

welder and a nut you dont care about FTW.


x2 this will be the best way cause the heat from the welder will break loose any thing cought in the threads

 

[eLindemann]

have you taken the intake off yet? if not take it off see if there is anything left to get a hold of use a little pb baster slight heat maybe if pb doesnt work and a stud extractor....

Yeah. The intake is off and sitting in my garage (nice and clean now though ) the remaining bit of bolts are almost flush with the rest of the engine.

welder and a nut you dont care about FTW.

Wish I had a welder, I can think of a million uses I'd have for it...

 

[SHOmethewayhome]

call some welding supply stores around you. a lot of times you can rent one for less than $75 (plus deposit of course) and it'll literally be a 10-15 minute job per bolt. luckily for you the intake bolts are much easier to access with then engine in the car than the damn thing i'm going after.

if you dont have access to a welder i suggest getting a good corded drill and doing it the way rubydist suggested.

 

[eLindemann]

if you dont have access to a welder i suggest getting a good corded drill and doing it the way rubydist suggested.

That's what I've got, so that's what I'll be trying.

 

[lowc]

if you can get some left hand bits

 

[mattsho1993]

is ther anyone SHO member in your area with a welder to assist you?

 

[eLindemann]

Got 'em out. For some reason, they really didn't feel like drilling out so I used my own method. I got really ****** off at them and started pounding a flathead screwdriver into the broken bolts. This turned them into flathead screws. Then I was able to twist them out as normal.

Thanks for all the advice, guys.