methods of getting out exhaust manifold bolts - 460 Ford Forum
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post #1 of 7 (permalink) Old 05-21-2013, 07:12 PM Thread Starter
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methods of getting out exhaust manifold bolts

I have one final bolt to get out of my efi 460... and the previous owner, or who ever tried it, has it so boogered up that it cant be drilled, its in the hole about 3/8 of an inch. not quite enough to thread a 7/16 bolt tapped in there. can i mig weld it shut even though it a cast head, and drill it from scratch? or should i try being delicate with a torch and only melting the remains of the bolt out while trying not to melt the cast...???? i cant go pulling the head off for 1 bolt right now but i would like to do something with it while its apart {i hate the sound of a leaking manifold}

Anyways, how do most dealerships and garages fix broken studs or bolts without removing the head? i have room to drill a hole, but like a said its to messed up to drill right now, thanks

77 f150 short bed , 466 chipped at 6800 , comp 292 cam , 2800 stall c6, 5.13's/ 38.5's
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post #2 of 7 (permalink) Old 05-21-2013, 09:30 PM
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It's surprisingly easy to remove a bolt from cast iron with a torch. The bolt will burn away and the cast won't. Try it on an old head first and you'll see what I mean.

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post #3 of 7 (permalink) Old 05-21-2013, 11:10 PM
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I have one final bolt to get out of my efi 460... and the previous owner, or who ever tried it, has it so boogered up that it cant be drilled, its in the hole about 3/8 of an inch. not quite enough to thread a 7/16 bolt tapped in there. can i mig weld it shut even though it a cast head, and drill it from scratch? or should i try being delicate with a torch and only melting the remains of the bolt out while trying not to melt the cast...???? i cant go pulling the head off for 1 bolt right now but i would like to do something with it while its apart {i hate the sound of a leaking manifold}

Anyways, how do most dealerships and garages fix broken studs or bolts without removing the head? i have room to drill a hole, but like a said its to messed up to drill right now, thanks
If I understand this correctly, you have an exhaust manifold bolt broke off 3/8" below the surface of the head? If you plug weld it closed the mig wire will mix with the cast and get very hard to drill & tap later.
I have used a mig, stick and tig to carefully spot weld "deposit material" on the tip of a broke bolt and build it out of the hole. I then take a clean steel nut and set it over the end of the built out stud and weld it on. Now take a torch and heat around the hole to help release the broke stud. Using a wrench on the nut, try to unscrew it out. It might brake off a few trys but it has worked for me many times more than not.
I have been able to use a torch to remove a broke stud but that process works best if the hole is not blind.
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post #4 of 7 (permalink) Old 05-22-2013, 04:28 PM Thread Starter
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I have done that welding trick before but i think it's to deep and I couldn't get enough penetration without touching the head itself

77 f150 short bed , 466 chipped at 6800 , comp 292 cam , 2800 stall c6, 5.13's/ 38.5's
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post #5 of 7 (permalink) Old 05-26-2013, 02:47 PM
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I have done that welding trick before but i think it's to deep and I couldn't get enough penetration without touching the head itself
I took my heads to a machine shop to get the broken ones out. They took a torch and carefully heated the bolt and as soon as it turned cherry they hit it with a blast of oxygen and it blew the bolt right out. They ran a tap through the hole to clean the threads. I asked them why it didnít hurt the heads and they said it was because they were dissimilar metals. I think I would practice on an old head before I tried it.

Gary

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post #6 of 7 (permalink) Old 05-30-2013, 08:03 PM Thread Starter
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Torched them out and tapped. All is well

77 f150 short bed , 466 chipped at 6800 , comp 292 cam , 2800 stall c6, 5.13's/ 38.5's
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post #7 of 7 (permalink) Old 05-31-2013, 08:20 PM
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Torched them out and tapped. All is well
Great News.

Gary

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