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Unread 05-14-2019, 03:33 PM   #41
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Default Re: Damaged cylinder head

4 header bolts broke off. I assume you broke the exhaust manifold bolts off in head that you called headers

You are not the first person thats ever broke one of these

I turn the cylinder head on side where I can apply light heat from my torch and then turn off torch and spray PB Blaster around threads.

I keep spraying small amounts of that blaster oil until it cools. When it expands it will let the blaster get down where you should be able to get it loose with vise grips but you have to let it cool completely. If you can weld then weld a nut on the broke stud and use a socket to remove it.

Never failed to get a broke off bolt yet but it takes patience . I have removed hundreds of broke off bolts and studs in my life.

We have no machine shop around here so I had to learn how to do these things myself many years ago.
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Unread 05-14-2019, 04:48 PM   #42
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Default Re: Damaged cylinder head

If you can the bolt welded on method is pretty reliable.
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Unread 05-14-2019, 04:54 PM   #43
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Default Re: Damaged cylinder head

Quote:
Originally Posted by CP241 View Post
Meguiar's wheel cleaner. Get the strong stuff with the acid in it (look in the ingredients). It will make the aluminum shine like new again. I use it on 4wheelers that the motor is now black/brown and stained with mud because the previous owner thought it was a submarine...



look at the brake cable adjuster nuts on this Honda Foreman ("T" nuts next to the brake). The entire rear diff and back of the brake was that brown color...
That looks nice. I'm here at Walmart right now. But nothing says acid. Theres a blue bottle(clear bottle, blue liquid) that say it's for aluminum wheels. By meguiars. That the stuff? Maybe they have a poor selection.

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Unread 05-14-2019, 06:07 PM   #44
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Default Re: Damaged cylinder head

Mine came in a purple bottle. Any acid based wheel cleaner will work.
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Unread 05-14-2019, 10:15 PM   #45
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Default Re: Damaged cylinder head

Quote:
Originally Posted by trig123 View Post
4 header bolts broke off. I assume you broke the exhaust manifold bolts off in head that you called headers



You are not the first person thats ever broke one of these



I turn the cylinder head on side where I can apply light heat from my torch and then turn off torch and spray PB Blaster around threads.



I keep spraying small amounts of that blaster oil until it cools. When it expands it will let the blaster get down where you should be able to get it loose with vise grips but you have to let it cool completely. If you can weld then weld a nut on the broke stud and use a socket to remove it.



Never failed to get a broke off bolt yet but it takes patience . I have removed hundreds of broke off bolts and studs in my life.



We have no machine shop around here so I had to learn how to do these things myself many years ago.
Yes Sir. The exhaust manifold bolts.
I've been watching a bunch of YouTube videos to get some ideas. Tried the heat and wax method with no luck. The wax did get sucked into one of the bolt threads but did not loosen it any. I thought that method was odd but I tried it. I've come across that blaster stuff a lot just never used it. I'm going to try your method tomorrow after work. I'll weld some nuts onto them as well. Thread them on about half way and fill in with weld. I'll get some pics up for you guys. Thanks again.

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Unread 05-14-2019, 10:59 PM   #46
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Default Re: Damaged cylinder head

Just make sure when you try and remove them to let the head cool after you spray the blaster. It's sort of tricky getting broke bolts out of aluminum but it can be done. Just don't get it too hot like you would when heating steel.

Light heat. I am very careful with aluminum. These 295 heads are getting rare in good condition.

I have also used Kano KROIL Penetrating Oil. I think it is probably the best but rather expensive. Auto parts stores normally don't stock it. People who work on guns swear by this. You can read the reviews on Amazon. All good.

Just be careful when heating anything. I have been in a shop for well over 50 years and I am still very safety minded when using an acetylene torch.

I still think maybe that head got too hot in the fire but time will tell. You won't be out much giving it a go. It was free which is always good Good luck.
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Unread 05-15-2019, 07:06 AM   #47
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Default Re: Damaged cylinder head

If there is enough bolt sticking out, these and a manual impact driver (the kind you hit with a hammer, not an impact gun) work wonders. The shock from the hammer plus the twist does a great job. Definitely one of those "must have" tools for any toolbox.

https://www.irwin.com/tools/screw-bo...-extractor-set
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Unread 05-20-2019, 09:04 PM   #48
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Default Re: Damaged cylinder head

So still no luck getting these broken bolts out. I've tried the heat with PB Blaster, vice gripswere no luck. tried to weld nuts on to the bolts but the nuts just turned off the thread real easy. I do believe they are stainless steel bolts. I do have a stainless steel rod for my Tig welder. I'll try that tomorrow. If that don't work I'll try to dissolve the bolts out of the head with the Alum, water and heat method.
Couple pics I took quick.

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Unread 05-20-2019, 10:37 PM   #49
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Default Re: Damaged cylinder head

They are not stainless steel.
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Unread 05-20-2019, 11:25 PM   #50
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Default Re: Damaged cylinder head

I think it's time for a decent stud puller tool, The Snap-On brand is my favorite but not cheap. Maybe you could borrow/rent one or maybe try this one from Kegs, It's similar but I've never used it so don't know how it is....

The way I've always done it;
Get the aluminum hot around the stud without getting the stud itself hot and try immediately while it's hot, But go easy and by hand at first. Then if you have to, resort to an impact. But you take the chance of breaking them off all uneven and harder to center a center punch to drill em out.......

OR;

Go ahead now and cut/grind the ends nice and flat, Center punch them and drill em for an easyout. I prefer to use a left handed drill bit for this as sometimes it'll grab the stud and turn it out for ya (If yer lucky), drill the hole as big as you can without getting into the threads. If you still can't get em with an easyout then drill em all the way and use a heli-coil and replace with studs..Good Luck

On a side note;
I'll bet those poor bolts are hardened now from all they've been through, not only exhaust bolts but the fire and from what heat you've given them already. Drilling may not be an easy job, but it can be done. Keep the bit cool go slow and easy

https://www.jegs.com/i/JEGS+Performa...yABEgJui_D_BwE
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