Broken bolt in head

Small Block Mopar Engine

  1. Dennis Gerard

    Dennis Gerard Well-Known Member

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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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    Last edited: Nov 21, 2020
  2. ch1ll

    ch1ll FABO Gold Member FABO Gold Member

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    If you’re in the Milwaukee area, bring it over. I’ll get it out.
     
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    • Treblig

      Treblig Well-Known Member

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      Can you post a close "clear" pic. I'm a machinist.
       
    • ch1ll

      ch1ll FABO Gold Member FABO Gold Member

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      51265A28-71E1-4B94-B19E-B0AF6411620C.jpeg Pardon the dust, just finished tuck pointing the inside of the shop.
       
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      • Northern Grit

        Northern Grit Well-Known Member

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        You might be able to bust up the easy out with a punch then vacuum out the crumbs.
         
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        • rustycowll69

          rustycowll69 Well-Known Member

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          I've done that on big holes, but I'm not sure that would work very well on small holes like for v. cover fasteners.
           
        • Treblig

          Treblig Well-Known Member

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          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.
           
        • oliver

          oliver Well-Known Member

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          That oil looks kinda milky.
           
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          • Treblig

            Treblig Well-Known Member

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            I saw it too but didn't want to say anything.....one problem at a time.
             
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            • Daves69

              Daves69 Well-Known Member

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              Small flat washer and nut weld trick?

              Does all you oil look like that?
               
            • Treblig

              Treblig Well-Known Member

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              If you have a carbide burr you can also carefully grind away the broken easy out or tap.
               
            • Dennis Gerard

              Dennis Gerard Well-Known Member

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              it is but from when I was working on water pump and power steering ...was going to change it next
               
            • Dennis Gerard

              Dennis Gerard Well-Known Member

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              This is the car 318 auto

              Fade 1(2).gif
               
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              • oliver

                oliver Well-Known Member

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                Oh. Did some coolant run into the oil or something and mix?
                 
              • Dennis Gerard

                Dennis Gerard Well-Known Member

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                Yes had bolts out to put in new bracket for power steering, other then thatcar has not run
                 
              • Tooljunkie

                Tooljunkie King of cobble/master of the broken bolt FABO Gold Member

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                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.
                 
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                • rklein383

                  rklein383 Well-Known Member

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                  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.
                   
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                  • JBurch

                    JBurch FABO Gold Member FABO Gold Member

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                    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.
                     
                  • diymirage

                    diymirage HP@idle > hondaHP@redline

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                    Seems like I JUST read this exact same problem on here, dont think it was over a week ago
                     
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                    • jimjimjimmy

                      jimjimjimmy lobsterman FABO Gold Member

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                      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 .
                       
                    • RammerJammer75

                      RammerJammer75 Well-Known Member

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                      I got deja vu reading this thread.
                       
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                      • diymirage

                        diymirage HP@idle > hondaHP@redline

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                        Right down to the silicone
                         
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                        • RustyRatRod

                          RustyRatRod Bla de blizhibliz de blatde blizi bla bla

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                          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.
                           
                        • JDMopar

                          JDMopar Well-Known Member

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                          Tape up that transmission dipstick tube if you ain't done it already! :eek:
                           
                        • pishta

                          pishta I know I'm right....

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                          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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