Bad bolt extract plz

[scratchedup]

I'm about to acquire a used intake manifold. It has a jammed/frozen bolt in one of the EGR attach passages. The bolt I assume is oem steel and the mating surface is aluminum. Previously it is was drilled and two EZ outs were broken trying to extract it.

There is a lot of info here on this topic but this is very specific with pictures. Also, I'm a little concerned about heating the aluminum.



back side-


Sent from my iPad

 

[78Bird]

drill it out and heli-coil it.

 

[allinon72]

x1 there isn't much left and what is is mangled. Drill it out.

 

[sberry]

Shoot if full of wire weld, a couple shots at a time to let it cool, when its full weld a washer over it. don't worry about a little heat, aluminum is relatively easy to do.

 

[scratchedup]

Shoot if full of wire weld, a couple shots at a time to let it cool, when its full weld a washer over it. don't worry about a little heat, aluminum is relatively easy to do.

Im learning here....
"full of wire weld,". What does this mean?

Wire weld from a mig machine?

 

[scratchedup]

Oops.

 

[motormitch]

I would give it another try using a left handed drill bit. Worse case, you end up drilling too much and then you heli-coil it. Easier to try then the suggestion about filling with wire weld unless you have a welder and know what you are doing. It is a good solution, but something an experienced welder should do.

 

[scratchedup]

I would give it another try using a left handed drill bit. Worse case, you end up drilling too much and then you heli-coil it. Easier to try then the suggestion about filling with wire weld unless you have a welder and know what you are doing. It is a good solution, but something an experienced welder should do.

What about the heat and parafin wax soak technique?
I do have Kroil oil. Would this be helpful?

 

[sberry]

Yes, the weld out is not for everyone, as was suggested some kind of drilling method is more practical.

I had a couple of drill outs on the bench, maybe see if I can find them.

 

[scratchedup]

The hole is a 13/64". I do not yet have this in my possession.

 

[ilovevocs]

I would give it another try using a left handed drill bit.

This would be my approach. I would soak it with penetrating oil. If they are steel fasteners in an aluminum manifold it is likely a result of the fastener / thread degradation as a result of galvanic action. Their a slim chance in hell it might come out, but the left hand drill bit is one step closer to the heli coil.

 

[scratchedup]

This would be my approach. I would soak it with penetrating oil. If they are steel fasteners in an aluminum manifold it is likely a result of the fastener / thread degradation as a result of galvanic action. Their a slim chance in hell it might come out, but the left hand drill bit is one step closer to the heli coil.

The hole was drilled using a 13/64" bit. Can you recommend what size LH bit(s) to start with?

If it is only very slightly bigger than 13/64" then it will prob just cut. Seems it needs to be a size big enough to get a grip on the stuck bolt to turn it.