How to I get this bolt out??

[brewseadog]

Working on my 97 gtx rave/piston collision. I have one more bolt to remove from the exhaust manifold that was so stuck on I have stripped the allen bolt. All the other bolts are out and the back head removed. How can I get this bolt out?

Thanks.

Dog

 

[racerxxx]

I'll preface this by saying I'm very proficient with a hand drill and do not use easy outs. I would start by drilling the head off. What's nice is the stripped hex should keep you close to centered, the bottom of the hex is tapered to a point which will also keep your bit centered as long as you stay parallel with it. A 3/8" drill bit will get you do the outside diameter of the threads, but I would start with a bit that fits closer to the stripped diameter. So from the face of the screw you will need to drill in a heavy 1/2" depth and then the head will either fall off or you can pop it off with a cold chisel. Then the real work begins, working the manifold to break free the white powder of death that causes the head to strip. The getting the rest of the screw out. This could all be a crap shoot so be forewarned.

Head length of screw is .388"
Angle point of a 3/8" bit is roughly .125
Total drilling depth = .513" deep

Next hard part, getting a drill and bit in there, you might need a right angle drill. Not sure I would want to do that in house like you are, I would have pulled the engine. Also for the next time, degrease the engine before you open it up.

 

[brewseadog]

Thanks. Had some serious white powder on the other bolts but got them out. I've never had much luck drilling on stainless bolts as they seem so hard I get no where. Any trick to this or special bit to use? Agree on the degrease part. Obvious I'm a rookie. What do you think about slotting the head with a dremel then using a large flathead/socket adapter I have. It is pretty beefy but I'm afraid I would just rip the rest of the head off.

Or. should I try and get the other head off and lift the head and manifold out and work on it outside or take to a machine shop. Not sure it would clear all the obstructions to get the head/mani off at once.

 

[racerxxx]

I have a machine shop at my disposal and a very well stocked shop at home of drill bits. We use a lot of HSS (High Speeds Steel) drill bits from MSC and Mcmaster Carr and a few other suppliers. Let the bit do the work and use a lot of lube. Most guys just go at it wide open and no lube and either burn up the bit or work harden the stainless. Stainless needs to be drilled slow--like a 1/2" drill slow or slower. Not your typical high speed 3/8" drill.

I'm sure I'd get chastised for this but..... you could always just use a right angle grinder with a slim grinding wheel (Sait .045 thick) and just cut through the head and manifold. Yes, you read that correctly--sacrifice the manifold to save the cylinder. You can get a 787 manifold shipped for $20 on Ebay. Literally "cut to the chase" and just get it done. Check your local Lowe's they might have the correct M10 X 60mm long screws for the one you cut. This is all OUTSIDE the hull, meaning you remove the parts and do this on a bench. Or get a hold of minnetonka4me and see what he gets for a mani and hardware shipped.

Not knowing your background this all could be out of your realm, not sure. Or just drop it at a machine shop and let them have at it, not the cheapest alternative. Your still gonna be on the hook to remove the stud. I've always been fortunate (read with sarcasm) that the screws break off at the cylinder and I have to do it in a milling machine.


http://www.ebay.com/itm/1997-Seadoo..._Watercraft_Parts&hash=item43ccd3d0da&vxp=mtr

Here is the cut off disc I'm talking about, this will take you finger off in a second. I have diced a Suburban up with one of these, windshield pillars are no match for this thing!

http://www.mscdirect.com/product/de...__24478980664_c_S&026=-99&025=c&item=40107906