broken bolt on exhaust side, nightmare

[tavacska]

Well. When I tried to replace the broken rings on one piston, I also changed the upper and lower oil seals. And I also tried to clean the exhaust/water side as the manual suggests.

There is only one bolt broken when I tried to dissemble. And that bolt is really stubborn and become a nightmare now.
Please help.

First, it corrodes because of water. I tried to drill in the middle of bolt and then use the screw extract. But I failed and also broken the extract inside that bolt. Then I tried to drill through it and it misaligned the center because of the stuck extract head, which is very hard to drill.
Now I totally messed it up. Part of the thread already be drilled. The hole is enlarged and half of it still occupied by the remaining bolt.

Please have a check on the pics and tell me, if it can be restored.

This hole must be restored, because without it, water will go to exhaust part, which is proved already yesterday.

 

[tavacska]

There is one adjacent hole, in which there is no thread. I have tapped it but find out there is no where to put a bolt on it. The outside water cover has a narrow support on that hole. The bolt can not be installed there.

I tried to start the motor yesterday to see if it is ok without that bolt. All the 3-6 cylinders flooded with water. Water also spilled out of the screw around all the screw holes around the broken one. That thread has to be recovered.

I think I may need a shop or professional help to recover this. Any suggestions in Houston area? I have no connection or experience with any mechanic shops.

 

[Scott Danforth]

this is where the remainder of the bolt with the broken off screw extractor will need to be machined out. then the area welded up, dressed off and re-tapped.

as they say, all 20 minute jobs are one broken bolt away from a 3-day ordeal

 

[tavacska]

Can it be done by machined out and tapped with a bigger size bolt?

 

[Scott Danforth]

with the broken off hardened bolt extractor stuck in there....no. the aluminum embossment will need to be cut out and then weld repaired.

some places could potentially wire-EDM the bolt out, however that usually scars the crap out of the base metal and the hole needs to be welded up and re-machined anyway.

 

[tavacska]

with the broken off hardened bolt extractor stuck in there....no. the aluminum embossment will need to be cut out and then weld repaired.

some places could potentially wire-EDM the bolt out, however that usually scars the crap out of the base metal and the hole needs to be welded up and re-machined anyway.

Thanks.

 

[tavacska]

How much labor is reasonable if I get a quote from workshop?

 

[Scott Danforth]

each shop is different. I have an independent welder/fabricator that I use that would probably charge $50. you will have to check.

 

[tavacska]

each shop is different. I have an independent welder/fabricator that I use that would probably charge $50. you will have to check.

Thanks. My first thought is it will cost me a fortune.

 

[Scott Danforth]

you wont know that until you ask around.

 

[tavacska]

A little update.

I called local work shops, about ten of them. Only one give me reference to a machine shop, but the machine shop doesn't respond. Several of them says they can not help, I need find a machine shop. The others never respond. I guess the job is worthless for them.

I did my work with tiny drills around the stuck extractor and get that out. Then, here and there get the remaining bolt out. but the hole is enlarged to 3/8 and has to be tapped.

The cover also need to enlarge the hole to fit the new bolt. The bolt can hold now for 21.5 lb.ft.

Thanks.