If you drilled 1/4" through the bolt, you may be able to use a pick and pull out the remnants. Then clean out with the correct tap. Just go slow and easy.

An easy out would work, but it is ahrd to get a good quality easy out that snmall that would not just snap off.

 

what´s your method of heating?

 

I used a butane torch but it didn't get it very hot. I'm going tonight to get some left hand bits and easy out. What size do I need??

 

I think bolts are 3/8" but I may be mistaken. It has been a long time since I did mine. Typical plumbers type butane torch doesn;t have a small enough tip to heat just the bolt as well as it should be. Small Oxy-Acet torch would be best.

 

Try and avoid using the easy outs...... they are very hard, but, brittle. They break relatively easily, and then you have a REAL problem.

I drilled an 1/8th inch hole thru my bolts, all the way thru, then used a torch to blow the rest out. Ran a tap down them, and nice and clean. The head can transfer a LOT of heat away, so, no real danger of screwing it up. if you start blowing material off the head when blowing out the bolt though..... you are doing it wrong.

 

bolts should be 5/16-18. i used lots of mopar penetrant, and a hammer to beat the **** outta the bolt. cut a slot in the bolt, and out it came. though i eventually bashed a 1/4 socket on it to get it the rest of the way out.

 

I GOT THAT SUMBITCH. Heated the front on and off and sprayed with this freeze stuff and then reheated it with a acetylene torch. On the home stretch now....hopefully. the Hughes kit came with doorman gasket

 

Congrats.

 

Should I put some kind of rtv gasket sealer on the t-stat housing?

 

Yes. Hi Temp RTV please, thin bead on both sides of the gasket.