The War Wagon... decaring wars on the grocery store since 1966

[Shelty]

thanks, I if I can just get the manifold off i'll be fine. I didnt think to tap on the bolt heads, these are the first broken bolts Ive encountered so far. the rest came out fine.

I'll mess with it more tomorrow,

but the headers are nice and do tuck up neatly under the car and dont hand down low.

[68scott385]

http://www.sears.com/cental-forged-1-2inch-drive-stud-extractor-puller-remover/p-SPM213831557?prdNo=1&blockNo=1&blockType=G1

In my experience with broken bolts/studs, this tool is the only thing that has worked worth a crap, which may say more about my ability to effectively use pliers, vice grips, and/or channel locks.

Getting the manifold off is still the first priority. Worst case scenario you have to drill the bolts out. In that case, start with a small bit, 1/8", centered as best you can. Increase the bit size incrementally until you get close to the bolt size or start to get close to the side of the original bolt hole. Get the correct size easy out, gently tap it into the hole, gently turn the broken bolt out. If that doesn't work...well, it might be time to think in extremes.

In any case and as previously mentioned, use generous amounts of PB Blaster.

[Shelty]

hours worth of work today, maybe moved the manifold a millimeter. heat, pb blaster, pulling, prying more pb blaster.... yelling.

my drill wont fit in the space between the fender and the broken bolts.

trying to avoid having to tow this thing to the exhaust shop.

short of pulling the passenger fender off, so I have clearance, im running out of ideas.other than to keep doing what im doing. I couldnt even pull the head if I wanted to, because the manifold is in the way of one of the bolts, and my luck one would snap as I took it off

[DanStokes]

Here's a thought. Can you pull the manifold toward the inner fender well? If so you can cut the offending bolts and get the manifold off - I suggest a Sawsall. Put the blade between the head and the manifold flange and be sure that if you gouge anything it'll be the manifold. Leave as much of the bolt as you can so you can grab the stub with Vice Grips and remove the remainder.

Another option - remember that the manifold is cast iron and therefore pretty brittle. If you're mad enough you can break that sucker to smithereenes. I don't think there's much value to it on the resale market and the scrap guy doesn't care if it's in chunks.

Dan

[68scott385]

Here's a thought. Can you pull the manifold toward the inner fender well? If so you can cut the offending bolts and get the manifold off - I suggest a Sawsall. Put the blade between the head and the manifold flange and be sure that if you gouge anything it'll be the manifold. Leave as much of the bolt as you can so you can grab the stub with Vice Grips and remove the remainder.

Another option - remember that the manifold is cast iron and therefore pretty brittle. If you're mad enough you can break that sucker to smithereenes. I don't think there's much value to it on the resale market and the scrap guy doesn't care if it's in chunks.

Dan

I was thinking along those lines but didn't want to be the one to suggest any of it. It's easy to see in your(my) mind what to do or what needs to be done but explaining it is another matter completely. I find that we think in ways to approach a problem by what tools we have on hand which may not always be the case with the person in a jam.

[Shelty]

thats currently what im trying to do, im trying to get the manifold to come far enough off the head to get some room in there for the sawzall. leaving enough of the bolt left to get vice grips on.

I didnt think about just breaking the manifold to pieces. thinking if I could break the top off of it, I could get my drill in there, drill down perpenduclar to the bolt (using a big bit) to basically cut the bolt in half then I could probably get the sucker off.

going to go back out in a bit to have at it again. just frustrating, an afternoon job turned into probably a week.

[68scott385]

an afternoon job turned into probably a week.

That's the situation we all face when starting a project, just have to make the best of it. What doesn't kill you just makes you stronger and you'll learn something from this that will help you out later, that is unless you get disgusted with the hobby and quit it altogether.

[Shelty]

true that, but im not quitting nor am I letting this car beat me.

working on drilling out the bolts, the manifold now wiggles a decent amount. so progress.

[68scott385]

true that, but im not quitting nor am I letting this car beat me.

working on drilling out the bolts, the manifold now wiggles a decent amount. so progress.

That's the only attitude to have doing this kind of thing for fun or money.

[Shelty]

good news, after three days of drilling and fighting with the passenger manifold it finally came off. surprisingly, the studs of the bolts threaded right out, no muss no fuss.

at least that nightmare is over with

[Scott Liggett]

You have discovered the first rule of hot rodding. Nothing is ever a simple bolt in. Nothing. Congrats on winning the battle of rusty bolts.

[68scott385]

If I had a nickel for every time something that was suppose to be a simple 30 minute job but turned into an all day nightmare...

Congrats on completion!!!

I don't suppose you took any pictures during your torture session? Or of the end results? Yeah, I know, it's set of headers bolt to a sbc.

[Shelty]

I can take a picture of the manifold.

[68scott385]

I guess I'm unnecessarily giving you a hard way to go, it's just that I get so much more from visual stimulation.

[Shelty]

its no problem lol, i didnt take any pics of the process of getting it off, cuz i was too busy fighting the thing.

just trying to get motivated to go out to the garage to get the pass side header on.