Re: [DML] Re: advice on stubborn bolt

["L. Sandel" <ls@xxxxxxxxxxxxxxxxxxxxxxxx>]

I had the exact same problem last summer - broke both of the rearmost bolts 
on that same part.  Broken an extractor off in one of the bolts, too.  Used 
a hammer and ice pick to get the extractor out.

I soaked them for weeks, literally.  I sprayed them with P'Blaster twice a 
day for 2 weeks.  Went through a few sets of extractors.  I torched them. 
Beat on them.  Carved slots in them and tried to remove them with a 
screwdriver.  Kicked, screamed, prayed, cursed, bribed, etc.  They were not, 
under any circumstances, ever going to come back out intact.  I knew I was 
in trouble when I first removed the intake, as there was a lake in the 
engine valley & the remnants of what appeared to be, at one time, a soft, 
furry animal.

Finally, I just drilled & tapped to the next size.  I think they were 7mm, 
so I drilled them to 8mm.  Or whatever the next size up was.  I even managed 
to lightly pierce the water jacket on one side.  YAY!

Anyway, I wrapped the new, larger bolts in a lifetime supply of teflon tape 
& reinstalled the cooling pipe.  I pressure tested the system - 3 times in 
two days (just to make sure everything was going to hold for a few cycles). 
It held 15lbs for an hour, which I took to be a satisfactory result & 
reassembled the remainder of the engine.  It runs fine.  No leaks, drips, or 
errors.

So, to make a long story sort - you may want to consider tapping them up a 
size.

-Luke
10270 





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