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exhaust manifold

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mss3020

05-29-2007 18:32:59

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Well I got myself into one NEED HELP. Replacing the exhaust manifold gaskets. Had one that was half gone and was a tad loud. So started the tractor up and got it all nice and warm. All the bolts came out except one. the head on the bolt was kinda rounded. So I cut the head off the bolt and took the manifold off over the bolt. I worked and worked to get that off. Nothing. So I thought Id cut stud off even with head and drill it out and hopefully retap. In the process of drilling my pilot hole ...broke the bit off in the bolt. So now what do I do. Is there a drill bit that is tougher than normal bits to drill the bit out of the hole. do I drill a larger hole and weld a stud onto the head and leave it that way. Any and all wisdom is needed.

thank you,

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DouginMI

05-30-2007 05:01:10

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Re: exhaust manifold in reply to mss3020, 05-29-2007 18:32:59

How about using a die grinder or dremel with a small carbide or diamond bur? Use it slow and steady like a drill. Or Hougen Man. makes a mill that looks like a holesaw. You can drill around the broken drill bit. I've used these before they work great but not cheep! www.Hougen.com Hope you get out of this without any more trouble.
Doug

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SamMI

05-30-2007 03:37:15

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Re: exhaust manifold in reply to mss3020, 05-29-2007 18:32:59

Never tried this however I was told once that if you can get sulfuric acid in that hole it may losen up the bit.

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37 chief

05-29-2007 22:27:37

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Re: exhaust manifold in reply to mss3020, 05-29-2007 18:32:59

Ever try to cut cast iron? It doesn't cut, that is why you can use a cutting torch to cut out the broken drill and bolt. If you spend too much time with the torch in the hole it will mess up the threads by melting the head cast iron. Just be quick. I have done this. I am about ready to cut out a couple broken studs on a ford 60 v 8 block. Stan

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135 Fan

05-29-2007 19:58:41

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Re: exhaust manifold in reply to mss3020, 05-29-2007 18:32:59

Try like Bo said. Weld a nut or piece of flat bar with a hole in it the same size as the stud. The rapid heat from welding expands the stud and then usually breaks it loose when it cools for a few several seconds. Dave

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RodInNS

05-29-2007 19:35:47

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Re: exhaust manifold in reply to mss3020, 05-29-2007 18:32:59

I'd try breaking the bit out with a punch. Failing that, drill a larger hole into the broken bit so you can get a hold of it. They're often loose in the hole even though they're broken. Sometimes a needle nose will work wonders IF you can grab it. Failing that, heat... and see if that softens the broken bit. Then try to drill it again.... but I'm pretty sure if you can't extract it with the plires, it will break with a punch.

Rod

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Steven@AZ

05-29-2007 19:18:06

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Re: exhaust manifold in reply to mss3020, 05-29-2007 18:32:59

I've had a machine shop remove something like that on a block once - then they checked the block for cracks and I threw it away, but they still charged!

I have also burned a bolt out and saved the threads. Don't get the head hot, it will probably crack...

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Leland

05-29-2007 19:10:20

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Re: exhaust manifold in reply to mss3020, 05-29-2007 18:32:59

take a center punch and break the bit into small pieces wear goggles to save your eye from flying steel

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Paul from MI

05-29-2007 18:45:25

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Re: exhaust manifold in reply to mss3020, 05-29-2007 18:32:59

Kinda bad news! Depending on if the drill bit was high speed steel(most likely) or plain carbon steel, you can try heating th e bit to a dull red and holding it for a few minutes the let cool slowly. If carbon steel, the broken bit will be softened enough to drill it out. If it"s high speed steel it probably won"t soften enough to drill it. The only sure fire way is to remove the head and take it to a machine shop that has EDM(electrical discharge machining) equipment. They can burn out the old stud and the broken bit without heat or damaging the head. Probably a good idea to re-surface both the head and the manifold before reinstalling. I would invest in some stainless steel studs and use lots of anti-sieze on the threads. I won"t say it works perfectly, but it"s a pretty good guarantee you won"t take off that manifold ever again if you prepare for it in advance. It is Gumpermans Law or something.
Paul

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05-29-2007 18:41:26

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Re: exhaust manifold in reply to mss3020, 05-29-2007 18:32:59

You could weld a nut to the stud and then wrench it out after soaking with PBlaster. Or...all else fails, burn it out. If it is into cast iron, chances are real good that you can burn it out without destroying the threads.

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MSS3020

05-29-2007 18:47:39

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Re: exhaust manifold in reply to bo, 05-29-2007 18:41:26

thanks bo.. after heat failed I ground the bold off next to the wall so I could get a square shot at a center hole through the bolt. I was itleast 1/2 inch into the bolt when it broke. I figure about 1/2 inche bit remains. So torch it out?? Ill try anything now..I need the thing working for hay thats coming.

thanks

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05-29-2007 18:50:54

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Re: exhaust manifold in reply to MSS3020, 05-29-2007 18:47:39

I've only done it once and only because I was out of choices....got the torch and got a pinpoint flame and went after the bolt. It just flew out of the head and I was stunned that the threads in the casting were still perfect. Worked for me.

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05-29-2007 18:39:50

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Re: exhaust manifold in reply to mss3020, 05-29-2007 18:32:59

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