Posted by Gary on Thursday, September 06, 2001 at 8:59PM :
In Reply to: Intake/Exhaust manifold bolt removel posted by WC12 Joe on Monday, September 03, 2001 at 1:43AM :
Start with the casting cold then use a welding torch with a medium size welding tip.
Heat the area of the manifold where the bolts to be removed are threaded in, take care not to heat the bolt head or any exposed part of the bolt that you are going to remove. Once the above described casting area is red hot, gently try to unscrew the frozen bolt, it should come out without a lot of effort, sometimes they groan or squeak on the way out. This almost always works, occasionally if the bolt does not budge I will let it cool and the rap on the head with a hammer and then repeat the process over.
To remove the broken bolt, find a thick washer that the center hole is a tad larger than the diameter of the bolt to be removed. Place the washer centered over the broken bolt and then reach through the hole in the washer with a wire welder and weld the washer to the broken bolt (this technique keeps you from welding the broken bolt to the casting). Next find a nut with a large enough hole through it to allow you to reach through the hole and wire weld it to the washer. Now you have a washer welded to the broken bolt and a nut that you can put a socket on welded to the washer. Use the heat the casting technique and unscrew the broken bolt.
I have used this technique hundreds of times in my exhaust specialty shop, the drill and easy out routine rarely works on broken exhaust bolts------Good Luck--Gary
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