Broken bolt in head

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Dennis Gerard

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My 30 min job turned into a nightmare, went to put on my new valve covers today, Did drives side now problem went to passengers 4 bolts came right our then 5th seems like it was broken off by someone and they used a ton of silicone on it. To make it worst after close inspection there may be a broken easy out in it.

Any suggestion or is it machine shop time.

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If you’re in the Milwaukee area, bring it over. I’ll get it out.
 
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Pardon the dust, just finished tuck pointing the inside of the shop.
 
My 30 min job turned into a nightmare, went to put on my new valve covers today, Did drives side now problem went to passengers 4 bolts came right our then 5th seems like it was broken off by someone and they used a ton of silicone on it. To make it worst after close inspection there may be a broken easy out in it.

Any suggestion or is it machine shop time.

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You might be able to bust up the easy out with a punch then vacuum out the crumbs.
 
Doesn't look too bad. If it is an easy out you can get a center punch and a smaller hammer and attempt to make the easy out "back out" by gently punching it in the opposite direction. Make sure you go the right direction and at right angles. If it's a tap then use a punch to carefully bust it up (they are brittle). You'll need a pick or a scribe to pick out the pieces as you go.
 
Small flat washer and nut weld trick?

Does all you oil look like that?
 
If you have a carbide burr you can also carefully grind away the broken easy out or tap.
 
Carbide burr will get it out, but may end up oversize. I have watched videos of guy with tig, built it up and threaded the bolt out with a vise grip.
 
Even if you end of oversize, you put in a threaded insert or even helicoil it and will be a great fix. Very little stress on valve cover bolts.
 
Another possibility...........do you have access to ox-aceltline? Line the cutting tip up on the easy out, get it good and hot, then blow it, the easy out, out. Torch will not cut the cast iron of the head.
 
Seems like I JUST read this exact same problem on here, dont think it was over a week ago
 
5-32" X-TRACTALLOY BROKEN BOLT EXTRACTION ELECTRODE - Partsmaster

use these , you can gently build the stud up with these rods or you can lay a nut over top and weld through the nut until filled with weld and turn out . even if a stud is broke off down deep in a hole you can still use these as the flux fills the threads and protects them from the filler . i use these now for 25 years and never had one defeat me yet . i just pulled 4 broken off flush exhaust manifold studs from a 4.8 dakota a few days ago .
 
Well, it's been drilled before and off center. So that's also an issue. If you can get it out, I do believe drilling it for a heli coil and installing a heli coil will fix it though. It looks like there's enough left for that. It's gonna be a challenge.
 
Got a plasma cutter? I like the oxy method. blow the molton stuff out! Tried mig'n a nut on a busted stud, no penetration to the nut. Probably didnt do it right.
 
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