Broken Water Jacket Bolts

[jmburock]

I made the mistake of attempting to remove my water jacket cover on my 89 Mariner 3cyl motor last week. I snapped 8 of the 19 bolts holding it on. The bolts are grade 9.8 M8-1.25. Any suggestions of what kind of drill bits to start with to get them out. I am looking into Solid carbide bits followed by Left hand bits. I'm preparing to HeliCoil if necessary. MAPP gas isn't helping so far in removing the stubs that stick out. After reading the other posts, I will stay away from Easy Out type extractors. What kind of a shop would take on the job of removing these. ANy suggestions of shops in RI or SE Mass ??

 

[sschefer]

Re: Broken Water Jacket Bolts

There's a laser process that I had done on the exhaust manifolds of a 460 Ford once. The Speed shop that did it where I'm at went out of business and that was a few years ago. I'm not even sure it'll work for you but you might call around and ask.

 

[Chris1956]

Re: Broken Water Jacket Bolts

Before you drill, heat the area around the studs, remove the heat and spray some PB blaster onto the studs. As the metal cools it may pull some in. After a bit put more heat (watch for fire) and turn the studs with a small pipe wrench or vicegrip.

The best drills I could get at the local HW store were cobalt. Hopefully you have a drillpress, since it will be hard to be precise with a hand drill. Left hand drills are a real good idea, if you can find them.

 

[Moody Blue]

Re: Broken Water Jacket Bolts

Another trick I have had success with is to heat up the stub/surrounding area than apply parafin wax to the part. The wax wicks into the joint and acts as a lubricant helping to free it up.

Sometimes it helps to tighten the fastener just a bit if you can get ahold of it. Once you detect any movement, work the fastener back and forth in small increments. Never try to force it in one direction only.

 

[Plainsman]

Re: Broken Water Jacket Bolts

I took mine to a welding shop and they got them out, but it wasn't cheap

 

[jmburock]

Re: Broken Water Jacket Bolts

I took mine to a welding shop and they got them out, but it wasn't cheap

How much did you pay per broken bolt so I have a rough idea on what to expect ? I still plan to at least try to get em out. And I'm certainly not using any Easy outs.

 

[James R]

Re: Broken Water Jacket Bolts

I really shouldn't give you this process but you seem to be a nice guy.
If you can find a friend with a Mig welder have him weld a washer, of a size suitable for the bolt, to what is left of the bolt. Then weld a bolt to that, dead center. While it is all still hot apply an impact wrench to the new bolt and all will be well.

 

[Duckhunter71]

Re: Broken Water Jacket Bolts

Had the same happen here. The problem is the galvanic corrosion. It changes the metal at the molecular level.

I had to put the block on the old milling machine so I could center drill and then either mill them out or run a drill bit at about 5000 rpm to finish it out.

I tried the methods above. Did not work for me. Good ole shop time did it.

 

[jmburock]

Re: Broken Water Jacket Bolts

Thanks for the all the suggestions so far. I'm at a loss for a friend with a mig welder. Drilling them out and going to heli-coil. First lesson I learned is don't waste money on Harbour freight drill bits, even the "titanium nitride" ones. Garbage!!! Craftsman cobalt work beautifully. And with cutting oil from Sears , haven't broken a bit yet..

 

[Plainsman]

Re: Broken Water Jacket Bolts

How much did you pay per broken bolt so I have a rough idea on what to expect ? I still plan to at least try to get em out. And I'm certainly not using any Easy outs.

I think it was around $180 for 12 bolts