Sanpped/Over tightened head bolt!!!!!

[Hi Def]

First off,let me start by saying,I know this all could have been avoided "if" I just woulda did what I did in the first place,which was,BUY NEW HEAD BOLTS!!!

 

I had brand new Nissan head bolts and washers when I started this build. I shoulda known better but here's what happened.

 

I started building the engine after taking is semi apart to replace all the seals and what-not since I bought the motor used and it sat in a garage for a few years. Well,everything came apart fine and cleaned up very well. Engine was is great shape inside. I believe the owner's story about the engine now,forsure.

 

Anyways,I get it all cleaned and painted,put together,HEAD TORQUED DOWN,when I discover,there is 2 broken exhaust bolts!? No way I say... Take the head back off,and send it to the shop.. Buy another gasket kit for the timing and oil pan,clean it totally off again,and get the head back 2 days ago. Everyone tells me,BOLTS and HEADGASKET should be fine,since the engine was never ran or heat cycled.... Why I believed this,I still don't know. HENCE WHY I BOUGHT NEW ONES IN THE FIRST PLACE!!

So,I end up putting the engine back together lastnight and SNAP!!!! The ***:&!! head bolt snapped!!!! Omg,I say... Well,much worse then that,but I'm sure you guys/girls know what I mean..

 

Now I need,New head bolts,engine overhaul kit,and take it back apart(All again mind you) and possibly have to ship/transport it somewhere to get fixed and back again!? In that case paint it again? Wow!!!

 

Btw,my car is a 79 ZX coupe 5-speed and I swapping in a 83 turbo. F54 with a P90a... Factory everything on the engine. Wanted to get it running before putting any kind of real performance parts or work yet.

 

My question is,has anyone ever had this happen??? What was your solution to fixing it? My friend,who is btw,master tech,Audi,BMW, and Porsche,and has a 1400hp car himself offered to bring some specialized tools over,but I have to buy the bits.. Those can't be cheap!? Something about drilling out the hole,from smaller to bigger,untill almost thru the bolt and to the thread size.. OR I mentioned a machine shop... If I go the machine shop route,would I have to take the crank and pistons and stuff out???

 

I swear,I am losing my patients with this car!!!! This all started from a blown headgasket in a N/A. Head is,like welded to that block,I found this turbo motor to swap in with almost everything,inc auto tranny that's not gonna get used and now I'M the one killing it with a stupid mistake!!! Really starting to weigh on me.

 

Just looking for my options on how to repair/fix this self induced,avoidable problem. Was totally turning out to be a killer looking engine!!!! Now its gonna look like a pos cause,I'm about to ready to drive it with that broken head bolt!!!!!!!!! Seriously!!!!

Edited March 12, 2012 by Hi Def