"William Mcfadden" <billmc@no-spam> wrote in message
> I have a 2-cylinder Onan engine with rusted exhaust manifold bolts. The
> bolt heads are broken off. I tried drilling out one of the bolts and
using
> a bolt remover, but the bolt remover broke and is now stuck inside the
bolt.
The trick, if you didn't do it this way, is to drill a pilot hole into the
remaining shank at low speed with a titanium bit and some cutting oil.
Drill as far as you can, then tap the square bolt extractor as far as it
will go into the hole and use a wrench to turn that. Takes awhile.
Hard to imagine breaking one of those things but there are lots of machine
shops in the phone book, like Ed's on about 205th and Stark. They probably
have a lot more experience with that kind of thing and better tools anyhow.
-c
In article <YNkMa.6291$JY1.4565@no-spam>,
gatt <gatt@no-spam> wrote:
>>"William Mcfadden" <billmc@no-spam> wrote in message
>>
>>I have a 2-cylinder Onan engine with rusted exhaust manifold bolts. The
>>bolt heads are broken off. I tried drilling out one of the bolts and using
>>a bolt remover, but the bolt remover broke and is now stuck inside the bolt.
>
>The trick, if you didn't do it this way, is to drill a pilot hole into the
>remaining shank at low speed with a titanium bit and some cutting oil.
>Drill as far as you can, then tap the square bolt extractor as far as it
>will go into the hole and use a wrench to turn that. Takes awhile.
I used the drill bit that came with the bolt remover kit. Not sure what it
was made of, but otherwise I did what you described above. My theory: the
bolt remover I used was a cheap piece of junk.
>Hard to imagine breaking one of those things but there are lots of machine
>shops in the phone book, like Ed's on about 205th and Stark. They probably
>have a lot more experience with that kind of thing and better tools anyhow.
I found an automotive machine shop in my neighborhood that removed the bolts
and retapped the holes. It wasn't cheap, but it was done right and for much
less than the cost of a replacement manifold.
Thanks to those who replied.
--
Bill McFadden billmc@no-spam http://www.rdrop.com/users/billmc
CAUTION: Don't look into laser beam with remaining eye.