OlderThanMe Posted December 20, 2006 Share Posted December 20, 2006 I have three head bolts that are broken off right above the block's deck surface. I have an easy-out but it is a little small for a big bolt like the head bolt. What methods are there for removing broken head bolts? Even I have to take the block to a machine shop I want to know how they will remove them and how much they should charge. I have heard of upto $10 per head bolt removed... I thought about using a vice-grip on the bolts but I don't want to scratch the deck surface. I am going to replace the bolts with studs once I can get these old bolts out. Thanks guys. Quote Link to comment Share on other sites More sharing options...
OlderThanMe Posted December 20, 2006 Author Share Posted December 20, 2006 Here you can see one of the broken bolts at the top of this picture. It literally twisted apart... Quote Link to comment Share on other sites More sharing options...
dr_hunt Posted December 20, 2006 Share Posted December 20, 2006 Well, If I were you I'd drill the bolt on center after getting a good center punch hole to start with. Then I'd smack it a couple of good raps with a 3lb sledge. Then I'd heat it with a propane torch and melt some wax into the threads. Should screw out relatively easily. If not well, at least you tried. Quote Link to comment Share on other sites More sharing options...
OlderThanMe Posted December 20, 2006 Author Share Posted December 20, 2006 Thanks Doc! I'll try that this week!!! I just don't have a propane torch...I'll try the other stuff that I have the tools to do though. Quote Link to comment Share on other sites More sharing options...
z-ya Posted December 20, 2006 Share Posted December 20, 2006 I just did this on a block. I used a MIG welder to weld a 3/8 bolt to the head bolt. I first ground the tip of the 3/8 bolt into a cone, to maximize surface area for the weld. Then I welded the 3/8 bolt to the busted head bold, using as much weld as I could to make it strong. I let it all cool for 15 minutes or so, then heated the block around the broken bolt with a MAP torch. I put a pipe wrench on the 3/8 bolt, and the whole thing came right out. Quote Link to comment Share on other sites More sharing options...
OlderThanMe Posted December 20, 2006 Author Share Posted December 20, 2006 GENIOUS!!! Now I just need a MIG...lol Thanks for that idea Z-ya!! that would work great! Quote Link to comment Share on other sites More sharing options...
Ledphoot Posted December 20, 2006 Share Posted December 20, 2006 Start soaking them now with some PB Blaster, longer the better, much better stuff than wd40 and any aforementioned method is good... Quote Link to comment Share on other sites More sharing options...
randy 77zt Posted December 20, 2006 Share Posted December 20, 2006 i just use some liquid wrench and a small chisel-to tap it around to spin it out. Quote Link to comment Share on other sites More sharing options...
Dragonfly Posted December 20, 2006 Share Posted December 20, 2006 I was increadibly lucky when I had a head bolt break off on me... it looked very similar to the picture you have and I was going to take the whole thing to a machine shop but I decided since I had a pair of vice grips handy I would give them a try before pulling the engine and the bolt came right out. If you don't get as lucky as me I can say that melting wax as described by Doc is one of the best ways out there to get a stuck bolt out, I have used that trick many times over the years and it has always worked. Dragonfly Quote Link to comment Share on other sites More sharing options...
alexideways Posted December 20, 2006 Share Posted December 20, 2006 You could also drill it in it's center, heat it red hot then pour a bit of water in the hole, since you drilled, the metal around the hole will have more room to contract. Since metal allways contract more than it expanded, it should come loose by itself. What really helps in z-ya's technique is the heat from the weld itself. Quote Link to comment Share on other sites More sharing options...
80LS1T Posted December 20, 2006 Share Posted December 20, 2006 I have found that often bolts break off and you can just turn them out with a pair of vise grips pretty easy. No heat but lube usually helps. You might find that the bolt is not even "stuck" and will just turn out. I only have problems when I trying to take a rusty bolt out of a rusty hole. Then you get bolts that break off and the threaded part gets stuck/seized, this usually when it gets to be a PITA! Guy Quote Link to comment Share on other sites More sharing options...
Pop N Wood Posted December 20, 2006 Share Posted December 20, 2006 http://www.madelectrical.com/workshop/broken-bolts.shtml Quote Link to comment Share on other sites More sharing options...
ezzzzzzz Posted December 20, 2006 Share Posted December 20, 2006 Many of these suggestions should work for you. The problem is if any one of them fails you're usually hosed to try anything else. Here's how I typically deal with a broken bolt when material is still exposed above the surface. I take a piece of round stock (1" long is good) and drill a partial hole to just fit over the remaining stud. I then drill a smaller pilot hole all the way through the round stock. That hole is often the same diameter as the bolt at the valley of the threads. The idea is to make a guide which allows you to accurately drill all of the material out except the threaded portion. Once done, a tap is used to clean the hole up. I keep the guides for future use. A machinist could make up several of these with some standard partial holes (8mm, 10mm, 12mm, 1/4", 3/8", etc.)rather quickly with 1/8" and 1/4" pilot holes. Once the pilot hole is drilled in the broken stud you can progressively step up the drill size to remove material until the threads are just reached. Quote Link to comment Share on other sites More sharing options...
naviathan Posted December 20, 2006 Share Posted December 20, 2006 I have one of THESE and for a broken bolt with that much sticking out I'd take a cutoff wheel and put a slit down the middle then use the flat head attachment to the impact driver. Works really well on rusted frozen screws and bolts. Quote Link to comment Share on other sites More sharing options...
big-phil Posted December 20, 2006 Share Posted December 20, 2006 I have done the mig welder thing, and if you have a mig its easy. Quote Link to comment Share on other sites More sharing options...
joe d. Posted December 20, 2006 Share Posted December 20, 2006 dynamite! that'll getherdone. Quote Link to comment Share on other sites More sharing options...
OlderThanMe Posted December 20, 2006 Author Share Posted December 20, 2006 Sweet guys!! I just called a buddy from my old welding class that has a MIG and he says he'll help me out pull my old bolts out on Saturday. I love all the different ways put up that definitely would help me and others searching for how to remove head bolts! great stuff! Quote Link to comment Share on other sites More sharing options...
naviathan Posted December 20, 2006 Share Posted December 20, 2006 Sounds like this should be a sticky. Quote Link to comment Share on other sites More sharing options...
cygnusx1 Posted December 20, 2006 Share Posted December 20, 2006 make a thin shield out of spring steel to slip over the broken stud to protect the deck. Quote Link to comment Share on other sites More sharing options...
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