Broken exhaust manifold bolt

[fauxfour2]

So i am swapping the manifolds off the 403 in favor of long tubes. Well i have gotten all the bolts off except one that snapped almost flush with the head. Long story short i snapped the easy out in the bolt and have reached the limit of my abilities (i probably reached that limit right before i snapped the easy out) and think the only course of action is for someone to weld a nub or something i can get a grip on so i can try to get this bolt out. This seems like a stretch but anyone know of anyone who has mobile welding equipment in my area who can do this kind of thing. I fully expect to pay for the job. Ive tried to drill out the easy out with no luck. Any help would be appreciated. Located in Long Island NY. Thanks in advance for the advice and the roasting that is sure to ensue.

 

[ssn696]

How much easy-out is embedded? You might try a diamond burr in a Dremel. Then drill out the hole until you get to threads. Helicoil if you go too far.

 

[fleming442]

Drill and tap a new hole next to it, then add a tab to catch the flange. Have a tube of red RTV handy to seal the threads after you drill through the water jacket. That's what I did on the Rusterado, anyways

 

[olds307 and 403]

Which bolt? On Olds V8's, I find the top center bolt usually snaps. Those aren't necessary to install leak free headers.

 

[fauxfour2]

How much easy-out is embedded? You might try a diamond burr in a Dremel. Then drill out the hole until you get to threads. Helicoil if you go too far.

I'd say about an 1/8 of an inch of easy out has made a home in the bolt. looks like there is about a half inch of bolt still in there but if it is anything like the same bolt on the other side (which luckily snapped off with some of the bolt still hanging out so i was able to get it off) it had rust all the way to the back of the bolt. I was reading about carbide burrs, would that be a better choice over the diamond? I ask cause i only want to do this once.

 

[fauxfour2]

Which bolt? On Olds V8's, I find the top center bolt usually snaps. Those aren't necessary to install leak free headers.

Thats the exact bolt. Its the one that sits ABOVE the middle two exhaust ports. I was able to get the one out on the one side but this one is really fighting me. Is it really not necessary for the long tubes im putting on? That would be great and save me another trip to home cheapo.

 

[fauxfour2]

Drill and tap a new hole next to it, then add a tab to catch the flange. Have a tube of red RTV handy to seal the threads after you drill through the water jacket. That's what I did on the Rusterado, anyways

That sounds like it would work but is out of my comfort zone for my abilities. My luck there would be a set of 350 rocket heads in my future after that lol.

 

[fleming442]

The top, center exhaust bolt is unnecessary on an Olds. Use really good gaskets like Percy's Seal 4 Good or Remflex, and you should be fine.

 

[fauxfour2]

The top, center exhaust bolt is unnecessary on an Olds. Use really good gaskets like Percy's Seal 4 Good or Remflex, and you should be fine.

Hearing that from you and olds307 and 403 is music to my ears. I'm going to research the gaskets now. Thanks all for the help

 

[ssn696]

Carbide will probably work. Has to be able to cut into the hardened EZ out steel. Once it is removed, the rest of the bolt can be drilled with a normal bit.