Once I get it off I plan to do that unless it has major cracks. I'm just looking at options ahead of time.Why do you think you need a new manifold? If in doubt about the "flatness" of the sealing surfaces just run it down to your machine shop and have them surface the flanges.
On the short studs..and the flush one... weld a nut on to what remains. Use a wrench to spin out.Well it's off. 5 Bolts broke off. Three I think are long enough to get out but one is only about 1/8 inch out and one is flush. I'll try an easy out with those. Worse case scenario I'll have to drill and tap. What is best way to get the studs out that stick out a bit? One is 2 inches, one is 3/4 inch, and one is about 1/4 inch out. I've doped them all up with more Liquid Wrench now that I can get to them better.
The manifold looks pretty good still but probably will need resurfacing and truing up.
Yes. I would use a #2 spiral extractor (7/32" bit). Frankly, I'd try and avoid using a screw extractor at all.... if you break one of THOSE off you're really (pardon the pun) screwed.It looks like those exhaust manifold bolts are 3/16 diameter. What size easy-out should I plan to use? The Irwin #1 uses a 5/64 drill bit. Is that too small?
Grind the end of the stud clean, and drop some weld onto it by itself. Take a nut that'll fit over the welded stud and weld the nut to your weld.Welding nuts on was a bust. I could not get the stud to melt. I guess my little 110v Miller doesn't get hot enough. It melted the nut fine but never would fuse to the stud properly. I think it would have just twisted the stud off anyway. I think I'm going to have to drill them out and re-tap.
135* split-point HSS bits should work fine. Cobalt is a plus. Try a 1/8" bit to drill a pilot hole first.I have been able to drill and tap 3 of the 5 so far. To get around the potential walking problem, I bolted on the manifold and in the hole I inserted steel spacers that I used as guides for the drill bit. The spacers are 3/8 OD and 1/4 ID. I had to wrap a couple of winds of electrical tape to make them fit snug. Then I used a 1/4 inch pilot point drill to start a small hole in the center of the bolt. I then used a 1/8 drill bit to drill out the center then followed that with 1/4 inch. That worked well for 3 of the broken bolts. The last 2 I have the 1/8 inch drilled out but I cannot get any 1/4 inch bits to bite. I wonder if someone used grade 5 or 8 bolts in the past.
Any suggestions on what type bit to use? I've tried split point, pilot point, red helix; DeWalt, Milwaukee and Bosch.
I don't know about the 135* or HSS but I seemed to have best results with 1/8 inch DeWalt split point but I can't seem to find a 1/4 split point. All the local stores have in DeWalt 1/4 are speed tip. I found a 1/4 split point on Amazon and ordered it but what I got was a speed tip. But get this, the product number - DW1316 - is the same. In the pic on Amazon it is split point but on the package they sent me it is speed tip. I emailed DeWalt but haven't heard from them yet.135* split-point HSS bits should work fine. Cobalt is a plus. Try a 1/8" bit to drill a pilot hole first.