Broken Head Bolts #@%&*#@!

ski4life65
ski4life65 Expert Adviser
edited November -1 in HUDSON
I was taking the aluminum head off of a 308 that has been sitting since 1957, and broke 2 head bolts. I have already broken 3 drill bits and have got nowhere (less than 1/2 inch into 1 bolt). Any suggestions (other than buy a gross of new bits)? The head won't come of as the remainder of the bolts are frozen to the head.



Thanks

Don

Comments

  • Unknown
    Unknown
    I'm assumeing it's locked up --Might try this--50-50 acetone/trans fluid---See ifyou can rig some sort of dam around the bolt hole to keep the fluid there , maybe modeling clay , let it soak a few days , Bust up an old spark plug and brazz an air fitting to it, find the cylinder with valves closed and put all the air pressure you got in it to help disslodge the head . If you can figure a way to block off the water inlet/outlet of the block with something you would have to make you could air up the water jacket to put even more upward pressure on the head , BUD
  • PAULARGETYPE
    PAULARGETYPE Senior Contributor
    I would try krol it is a great penetrating oil. Spray it on hit the bolts with a hammer let sit a few days doing the same thing they will come out
  • lsfirth
    lsfirth Expert Adviser
    Okay....so if the bolt heads broke off, then can you get the head off the block??? If the head is off, can you get a pair of vise grips on the ends of the bolts?? I've heard that if you heat the ends of the bolts red hot with an oxy-acetylene torch, then let them cool, then they will come out easier....keep us posted on how it goes. Worst case, you take the entire bock to a machine shop, and they can mill out the old bolts and then you're off and running.



    keep us posted!!

    Lee
  • bob ward
    bob ward Senior Contributor
    If you are twisting the heads off the bolts, that means the strength of the corrosion between the bolt and the block threads and/or the head is greater than the strength of the bolt. Fairly obvious I guess. The first step is to try to reduce the holding power of that corrosion.



    As others have said, heating and/or soaking the bolts with penetrating oil may do the trick. When you are ready to try removing the bolts again use a rattle gun, I find the shock action of a rattle gun is useful for stuck bolts.



    When you finally get the head off and have a block with 2 or more broken bolts protruding from it there are different methods you can use. First one is more heat, more penetrating oil, stud remover or vice grips. Second one is cut the head off an old bolt, drill a hole to suit the bolt, weld it to the bolt, and attack it with the rattle gun. Third one if the first 2 don't work is to take it to a machine shop, just a neighbourhood 2 man show, not one of the big flash ones. They will mill the broken bolts out for you.



    Whatever you do don't use Ezy-Outs. If you do, you will still need to go to the machine shop, as they will have to remove the broken Ezy-Out for you.
  • barrysweet52
    barrysweet52 Expert Adviser
    You could also try welding a nut on the top of any broken bolt, and then follow the other suggestions. Regards, Barry
  • Unknown
    Unknown
    KRoil is great stuff but a test showed acetone/trans fluid beat all by about 10 to one force needed to remove after soaking . What you have is what alluminum allways does , grows a crud when coroding . Object for you is to soften it and since lube is not a factor it could be that pure acetone will soften it better . I still go with the air the water jacket to remove. you will have the max pressure of your compresser PER SQUARE INCH pushing up on the head, that's a bunch . I've done this to block them . Weld or brazz a plate on the end of a piece of pipe , drill and tap to screw in an air fitting and attach to engine useing heavy hose double clamped as a coupler . If you end up messing up threads when you fially get the stud ends out use HELI COILS to repair , you can do this yourself and is stronger than original threads . BUD
  • [Deleted User]
    [Deleted User]
    Don, I was able to drill out 3 or 4 bolts out of mine that had been broken off flush. I used a pilot bit (about 1/8" to go down through the center first, then graduated up to larger bits. Use good quality bits, and lots of the drilling oil. Also, I had removed my hood covers completely so I could get in good position over the center of the hole...slim
  • ski4life65
    ski4life65 Expert Adviser
    Driiled out bolts and got the head off. It's always a crap shoot with the old engines on what you will find. I just rolled snake eyes :( Beyond rusty. I will save this one for a full rebuild some day. Hopefully the hydramatic proves to be better. That's all I cared about anyways. Thanks for everyones help
  • [Deleted User]
    [Deleted User]
    ski4life65 wrote:
    I was taking the aluminum head off of a 308 that has been sitting since 1957, and broke 2 head bolts. I have already broken 3 drill bits and have got nowhere (less than 1/2 inch into 1 bolt). Any suggestions (other than buy a gross of new bits)? The head won't come of as the remainder of the bolts are frozen to the head.



    Thanks

    Don
    Do not use heat as you have an aluminum head and you can melt it with to much heat. If you do not plan on reusing it, then go with plenty of heat. Get CARBIDE DRILLS, as Hudson used the best material for engine parts. Use plenty of machine oil while drilling. Start with a small size drill and slowly go bigger. Walt.
  • [Deleted User]
    [Deleted User]
    Good to hear you succeeded Don. What we go through to keep our Hudsons going!
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