I will consider that when I have some time to kill.

 

Yeah I did read ALL 60 pages (took some time)!! I'm in the middle out the plenum repair. I ran into some issues and for the most part, when I asked a question I did get an answer. A few were contradictory but 1st, what worked/works for one guy could/can be different for another. Also not everyone knows what their talking about (not saying they don't mean well) the just don't know and/or havn't been there done that. I asked questions BEFORE & during, which I recommend. I can't speak for anyone but homework should be done! And lots of it. With all that said I've asked questions that people either just don't respone to or don't know the answer. I shot lots of pics and have lots of advise, tips and some tricks...So to anyone listening, just ask

 

TIP # 1: Never use an easy-out to remove a snapped intake manifold bolt!!!! Reason: You think you know how the process works (center punch the bolt, drill a hole starting with a small bit, and so on) then BAM the easy-out OR one of the bits snap inside the bolt hole and you can't get it out AND your in my position (lets just say it's not a good one) Solution: use a socket type bolt extractor!! vice-grips only work sometimes and in certain situtations..for more info just ask

 

so my question is how the h*** do you remove the bolt with a stuck bit in it out? I don't have access to welding equipment, so that's out. Can't drop $80+ on a drill bit. Don't have the $$ to have it towed to a shop (it's not the tow $$ it's the shop $$) So close, yet so far...

 

Get a center punch, and shatter the bit. pick out the pieces. Get as much out as you can....

 

Ok got it out last nite..I had to use all sorts of techniques. BUT, the hole is off center..It was my only choice, so now what?? I'm going to pop the IM back on and see how bad it is Any ideas, tips, advice? I really can't get a new cylinder head, nor do I believe I can/want to fill the void with JB weld. So I'm hoping a helicoil kit will do the job, IDK...So I guess nobody knows what is up with those gaps in the pics I posted?

 

Can you run a tap down it to clean up whats left of the original threads?

What gaps?

 

What if I drilled the CH hole larger. Then taped off the bottom of the hole, then put JB weld down in it, then a washer, then JB weld , then washer and so on to the top. Then used a helicoil kit?? FYI these are the front 2 bolts (either side of the cylinder head #'s 11 & 12)

 

Think I would be more tempted to just get some longer bolts, and use nuts on the bottom, since you can get to them..... can't leave the washer on top, as it would prevent the manifold from sitting correctly, and it would never seal. You would have vacuum, and coolant leaks..... not a good scene.

You might be able to get away with filling the hole with JB weld, and redrilling it in the correct position, tap it, and then helicoil, or not (tap to correct threads).... not like the bolts are torqued to huge values......

 

Part of the bolt is still 'welded' in there, so no tapping yet...Posts #'s 611-612 the gaps in the pics..I think they're self explanatory..I'm just not sure why they're like that..left side (driver side head) has a bigger gap than the right side (passanger side head) etc. I was hoping the JB weld+helicoil would work..If I 'have' to try the washer thing I would leave it flush with the top of the bolt hole in the head..just trying to figure what would work best. I'm still trying the get the rest of the bolt out. I'm using the IM to keep things centered..Once I get it out (if I ever do) I'll JB weld the hole and do what you said. Thanks!!!!