Older Box? Considering headers?

[eightsandaces]

I know this is going to sound bad but I can't remember being more pissed in 51 years. I now have a helio coil in my exhaust manifold I'm praying will sock up and one more to repair I'm praying won't end up a second helio coil. Besides that, the uber strong, splined threaded bolts in the cat converter? Three came out like butter, the other three I beat the **************** out of no no avail. I have no idea how to get those lower splines out except to rent a torch.

I'm serious when I say I very well may have wrecked my car and I'm so defeated I may just sell it for a huge loss if I can't remedy the rest of the repair, all in pursuit of sound and maybe 10 hp...

Any suggestions on the splined broken bolts other than the torch I don't have would be appreciated.

[mikefocke]

posted of the same issue over on PPBB complete with a running commentary and pictures of what he was trying.

It starts here http://www.ppbb.com/phorum/read.php?19,1551648,1551648#msg-1551648 but there may be a few more separate threads as the saga streatched over about 10 days IIRC.

Do not despair, read first and then consider the things he tried. It wasn't easy but your engine isn't wrecked.

[root_werks]

I agree, you haven't hit any point of destruction yet. Take a step back, let it sit for a day or even two. I've done that before, just let the project sit and come back to it refreshed.

Keep us posted.

[landrovered]

X2 step away from the car when frustrated, tired or hungry.

I had a head bolt round off on a V8 and after a few days of cogitating on it I was able to come up with four methods of getting it out. Number one actually worked without having to resort to welding a bolt on, drilling and tapping and other more extreme measures.

Heat is not even on the extreme list if it makes you feel any better.

[eightsandaces]

Wow, I never felt so much empathy from people I only know in type, thanks, it means a lot today. I just returned from renting a very good acetylene torch. I'm a bit reticent about using it, but I think it's necessary. I guess the only laugh today was the RR side came apart like butter... What concerns me the most is the helio coil, it's in there well, (I converted that hole to a stud) maybe it will suprise me and work right.

PS When I was doing my serpentine belt, I found the insulation above the area to almost be hanging into the belt path, I wanted to let EVERYONE know that. Also, if you are ever removing the tensioner, take the pulley of the PS pump, three bolts makes the job easier..

[root_werks]

Take that Helio coil out (looks like a spring correct?) and use a timesert:

http://www.timesert.com/html/mtrcsert.html

Done a thousand air-cooled Porsche-VW broken studs in my life. Coils are junk, don't hold up at all. Timeserts are the solution.

Keep the updates coming!

[schoir]

Originally Posted by eightsandaces

I know this is going to sound bad but I can't remember being more pissed in 51 years. I now have a helio coil in my exhaust manifold I'm praying will sock up and one more to repair I'm praying won't end up a second helio coil. Besides that, the uber strong, splined threaded bolts in the cat converter? Three came out like butter, the other three I beat the **************** out of no no avail. I have no idea how to get those lower splines out except to rent a torch.

I'm serious when I say I very well may have wrecked my car and I'm so defeated I may just sell it for a huge loss if I can't remedy the rest of the repair, all in pursuit of sound and maybe 10 hp...

Any suggestions on the splined broken bolts other than the torch I don't have would be appreciated.

Eights:

Don't despair, it can be done. Those splined bolts can be drilled out if you are patient and use the right tools. I recently went through the exact set of difficulties and was able to successfully drill out all of the broken studs and later drill out the splined bolts on the catalytic converters. I replaced them all with stainless steel fasteners.

Here is a photo of the remnants of the splined bolts on the cats:



Note that it is not a good idea to bang them out with a sledge hammer as you may damage the cats.

Take a look at this thread, it may give you some useful tips and some inspiration:
http://www.ppbb.com/phorum/read.php?19,1552044,1552044#msg-1552044

Also take a look at this thread for some more text and photos:
http://www.ppbb.com/phorum/read.php?19,1551648,1551736#msg-1551736

The key in drilling out the bolts is using that little dremel carbide bit if you don't get your initial mark dead center.

Hang in there!

Regards, Maurice.