So I go to take the intake manifold off and the first bolt I touch snapped off when I sneezed! It most have been rusted nearly completely through. I have already soaked the thing for a few hours with PB Blaster and tried locking vise grips on it. Any other suggestions?

 

i drilled threw mine since it just comes out the bottom and hooked a bolt to the bottom when i put on my new intake manifold .. i tried other stuff and it didnt wanna come out .. i still have a broken bolt in the back that i discovered taking it off,so i know someone tried to tackle the plenum before me. the bolt didnt even had a head on it

 

PB Blaster soak over night and heat in the morning with Vise grips on it as tight as I can get it, also try tapping it with a hammer to vibrate some of the rust loose. I had the same problem, same bolt on mine the first time I did mine, it took me a while to get it but it did come out.

 

if you have a welder, you could weld a nut onto the top of the broken bolt, then apply a wrench to the nut, combined with penetrating oil and heat.

and/or i'd try a plumber's propane torch, applying heat to the bolt, then try to turn it with the welded nut or vice grips.

also, if you don't have a welder, but do have a die set, you could attempt to cut/fix new threads on the broken bolt, then thread on a couple of nuts and lock them together.

heat's going to be your best friend. it stretches the bolt and breaks the rust lock.

 

An RPG?

 

I've actually had really good luck with these things. Might be worth a shot. http://www.craftsman.com/shc/s/p_101...yword=bolt+off

Welding a nut to it would be the easiest if you have a welder. Anybody ever tried that with JB Weld?

 

jb weld is good, but not that good. the torque would break it right off.

 

Chemicals, heat if ya got it, vice grips, and rapping on it with a hammer while trying to turn it works rather well. (as said above. )

I drilled thru mine, and then blew the rest out with a torch. Ran a tap down the holes, and all was well in intakeland.

 

well if you didnt destroy all of the threads on it i would have told you to get 2 nuts and screw them on, back the 2 nuts together and back it out.

but the best thing to do now is grind it in to a square and put a socket on it and take it out, or get a socket that smaller then the bolt and hammer it on, or jbweld a nut

 

I did something similar on a couple exhaust manifold bolts on my Camaro. I just ground two flats on them and used vise grips since they're 5/16" bolts.
Two nuts is a good one too, just crank on the bottom nut and it would lock together with the top one.