So I was in the process of doing my plenum and I broke the 2 front bolts taking it out. I tryed the notching and using a screw driver but that failed. One is flush with the block and the other is close to it. I started to drill one out and have gotten all the way through but still can't get anywhere with it. Anyone have and suggestions? Thanks

 

Drown them with chemicals. If you can get a grip on the one that is not flush with a pair of vice grips, clean the area where the bolt actually goes into the head, hit it with chems, grab the bolt with the vice grips, tap on the end with a hammer, while trying to turn it. (either direction, doesn't matter) It will eventually break loose, and once it does, it will come out.

For the one broke off flush, try going to slightly larger drill bits, till you are ALMOST cutting into the threads. Then just try and chase the rest with a tap. (3/8ths 16?)

 

After drilling the bolt for an easy-out, heat the bolt till its cherry red with an acetylene torch, then hit it with a punch + hammer to break it loose, then insert the easy-out to remove the bolt typically works for me.

 

My two front ones were rusted all the way through. payed a machinist 120 bucks to come to my shop and drill and tap it. Not worth the head ache to mess with it yourself. At least for me.

 

when i was doing my plenum i had the front one on the passenger side break, i cleaned all the grime away from it and soaked it with wd40 specialist rust release penetrate a few times and let it soak. but i also had about 1/2 inch of the bolt to grab with vice grips. Maybe try and soak it with pb or wd specialist and seeing if an easy out will work, ive personally never had any luck with them tho when a bolt is frozen. ive heard with the easy outs if you drill as much of the bolt that you can it helps with extracting it.

 

Thanks for the response guys. I went out and got a bolt extracting kit and a small tap set so il give it a try tomorrow. Not sure if it's gonna work but wel see. I noticed it goes all the way through so I wonder if there's a way to put a lock nut on the bottom with a little bit longer bolt. I guess that's my last option. Not sure if anyone else has tryed this or not

 

Buy some left handed drill bits, if your lucky the bolt will come out as your drilling it. The one that's sticking out you could weld a nut to it. This usually works best as the welding seems to loosen frozen bolts. If you can't weld a nut to the one that's flush, weld on a washer, then a nut to the washer.

The square easy outs have worked for me. Don't heat the bolt with the easy out in it, it wrecks the temper or hardness, and will just slip.

 

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