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Refusing to break another bolt...!!!

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bigtime_mcalpine

Regular Contributor
Any tips here? I'm working on a 9.9 powerhead and have got all but two of the exhaust cover bolts out. The remaining two are not budging. I'm not losing this battle. At this point it's personal. I've used some heat and I'm using a shorty ratchet with a six-sided socket to make sure I don't strip anything or break the bolt by applying too much torque. Things still are not budging. I guess I just keep going to town on it with heat and gentle knocking with hammer...any other tips? Penetrant is of no use here - there's no way it will seep in far enough.
 
The bolts are corroded and scrap.----Cut the heads off.-----Remove exhaust covers.------Use heat on the block and visegrip to remove the studs.
 
I have had some luck using a wrench, applying pressure and tapping with hammer at same time. May or may not work for you.
 
at half-time score stands at Pierre 1, Powerhead 1. Broke one and got the other out. Remains of bolt sticking out by a few mm. May be time to weld a nut on . If only I had a torch.
 
A manual impact driver is a good option in these situations. Heat the bolt then smack the driver with a hammer. The shock of the hammer whack and twist of the driver often gets stubborn bolts moving.
 
kevinj said:
A manual impact driver is a good option in these situations. Heat the bolt then smack the driver with a hammer. The shock of the hammer whack and twist of the driver often gets stubborn bolts moving.
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Good point. Alas, my manual impact driver (which I loved) is sitting in pieces on the grass. Damned thing just flew into pieces. Time for another.
 
Drill , heilcoil tap and helicoils.
I just did it to my Yamaha.
Broke 2 in the water jacket cover.
18 years of salt water build up causing overheating.
Runs without over heating now
 
Interesting finding - I was hesitant to drill given my VERY slow progress with brand new cobalt drill bits from Home Depot but ended up going over to Brofasco to get some REAL bits. Wow, those things just plowed through these studs like nobody’s business. Managed to get both out and aim was good enough to save the threads. Well, not quite - exhaust cover hole needed to be drilled slightly larger to compensate for slightly different positioning of the “new” hole but no buggy. Mental note, be sure to leave a nasty review for those $10 drill bits (each!) from HD. They are absolute ****e. Thanks for all the tips - next time I’m going to listen to racerone and cut off heads wherever access permits and just pull the studs out.
 
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