Broken exhaust bolt 6.0 LS

[AZlml]

I had a broken exhaust manifold bolt which I guess is a common issue, so I welded a nut on the end and snapped the bolt at the head. I then drilled it for an easy out and then snapped off the easy out.. After using a Dremel to grind down the easy out I now have a fairly large diameter hole in this bolt. I'm weary of using another (bigger) easy out at this point.. Heads are aluminum and the threads aren't in too bad of shape at the edge of this bolt (Dremel got away from me). Looking for advice before I go for it with the other easy out.

 

[Tothemax]

i always mig weld a tail to them and grab them with vise grips or weld a tail then a nut to them sometimes it takes a few nuts before the bolt will come out but always does. ive done hundreds that way

 

[duramaxnate]

What I usually do for aluminum is take it to an extraction shop. I don't like running the risk of doing damage to the threads or the head.
Any machine shop will either have a recommended place or some will do it in house.

 

[AZlml]

i always mig weld a tail to them and grab them with vise grips or weld a tail then a nut to them sometimes it takes a few nuts before the bolt will come out but always does. ive done hundreds that way

How would you weld a tail onto what's left of that bolt? There's no risk to the head that close?

What I usually do for aluminum is take it to an extraction shop. I don't like running the risk of doing damage to the threads or the head.
Any machine shop will either have a recommended place or some will do it in house.

The head needs to be off to do this I assume?

 

[mopar3]

You can mig weld to what is left in there. The weld will not stick to the aluminum. I usually just weld a little bump on at a time build it up till it sticks out and weld a nut on. The heat from the weld will free it up. May take a few tries to get out. Let the weld cool and the heat work to free it up.

 

[mopar3]

An easy out is the worst tool for smaller bolts like that. As you screw the easy out in it expands the bolt and locks it in.

 

[ironmax]

If the hole you drilled is lined up well you could just keep drilling it out and finishing up with a tap to cut out rest. Have had to do it a few times. Or drill it out and heli coil it.

Sent from my SM-J337A using Tapatalk

 

[Tothemax]

like said, wont stick to the aluminium. most of the ones i have done have been a couple threads below the surface

 

[Nickracer9]

I would soak with PB BLASTER A FEW TIMES AND LET IT PENETRATE. Some heat on the head like a blow dryer and try a new easy out. I’ve gotten plenty of that size bolt out with an easy out. Yes it will expand but the penetrating oil will reduce the friction.

 

[Tothemax]

 

[Tothemax]

i dont know why every picture i put goes super sized but you get the idea. these ones i welded tails to and used vise grips

 

[clrussell]

i always mig weld a tail to them and grab them with vise grips or weld a tail then a nut to them sometimes it takes a few nuts before the bolt will come out but always does. ive done hundreds that way

This exactly.

The weld won’t stick to the aluminum so no worrys of damage. Makes it a painless process compared to drilling and all that

 

[NC-smokinlmm]

Yep, weld away...

 

[Rancelot211]

Watch your drilling. Water jackets are behind the holes. Had a shop do this for me on my 01 when i had it. Ended up having to put a new head on.

 

[2004LB7]

Soak it in nitric acid. It will not touch the aluminum but will eat away the steel

 

[AZlml]

Got it! Thanks for the suggestions guys, worked great and no damage.

 

[Tothemax]

:thumb: