1978 evinrude 85 - broken bolt, plus hole in water jacket?

[nonstickseven]

Hello, so I recently purchased a boat with a 78 evinrude 85hp, and I'm just going through the motor and replacing anything that looks rough. I took the back exhaust cover off to have a look, and one of the middle bolts between the water passages broke off inside the block. Then I proceeded to break the extractor inside the bolt as well. I began to dremel the broken extractor out, then noticed there is a tiny little corrosion hole in the water passage where this broken bolt is next to. Looking for any thoughts or advice on where to go from here? I'm guessing the tiny hole corroded to where the bolt hole is in the block which is why it is refusing to come out. I'm thinking trying to get the bolt out of the block with success is becoming a slim chance if its terribly corroded . I've got a new gasket for the exhaust cover, should I slap it back together and see if there is any leaking around that bolt area? Here's a link to a pic: http://imgur.com/gallery/3xiZxs8

 

[DrCoxie]

Hello, so I recently purchased a boat with a 78 evinrude 85hp, and I'm just going through the motor and replacing anything that looks rough. I took the back exhaust cover off to have a look, and one of the middle bolts between the water passages broke off inside the block. Then I proceeded to break the extractor inside the bolt as well. I began to dremel the broken extractor out, then noticed there is a tiny little corrosion hole in the water passage where this broken bolt is next to. Looking for any thoughts or advice on where to go from here? I'm guessing the tiny hole corroded to where the bolt hole is in the block which is why it is refusing to come out. I'm thinking trying to get the bolt out of the block with success is becoming a slim chance if its terribly corroded . I've got a new gasket for the exhaust cover, should I slap it back together and see if there is any leaking around that bolt area? Here's a link to a pic: http://imgur.com/gallery/3xiZxs8

In my experience those bolts never come out, it's a ****ing nightmare so if i were you and had the cash to spare take it to a machine shop and ask them if they can drill it out for you and sleeve it or something. I wouldn't just slap it back together without that bolt since that will just create a leaky area, that bolt is there for a reason. As for the hole that's the least of your problems id say figure that out after you got the bolt dealt with. It might not even be a hole, you dont really know that it connects to that bolt do you?