Inspector12

iTrader: (29)

Installing a set of heads and was using a new set of factory head bolts. I blew the holes out threaded a clean out bolt in each one then blew them out again. Bolts went in fine I am on the final pass I get to about 45 degrees and snap ( Big bolt second one from the front on the outside). At first I thought the ratchet had slipped but no I wasn't that lucky. I am just looking for suggestions I know I can drill it and put a Helicoil or drill it and retap it to a larger size etc... What have you had happen and what did you do to fix it? I have only used the factory bolts 3 times now and two out of the three have ended up with broken bolts so I am washing my hands of them after this one. Oh by the way it is on one of the long bolts so it is about 4 inces down I can't see it with out a flashlight etc... I was doing this on new years eve to help a kid out that has to go back to school on the 6th etc.. Just put the icing on the cake for 2004 and making 2005 start off rough LOL!

99ssleeper

iTrader: (98)

You're not supposed to reuse the stock headbolts.

I have no idea how to easily fix it...and I dont know how much bigger you'll be able to drill it out or if that is necessarily the best thing to do anyway.

I guess all I can say is good luck!

Inspector12

iTrader: (29)

Yeah I know read the first line of my post it says NEW set of factory bolts. Thanks for your imput. Kinda cold up there right now?

Ojustracing

iTrader: (4)

Well if the bolt just broke. It should be able to be turned back out. Easier said then done down that far.

If it is stuck then there is something in the threads and you are going to have to drill the thing. Again Good Luck. Did the bolt screw right in or was it tight going in. From the sounds of it, that it surprised you when it broke. I would say the bolt was bottomed in the hole. I've done alot of TTY bolts and only had one break because we were in a hurry and didnt clean the crap out of one hole. But we new it was going to break. You could feel the bolt stretch, just like the feel you get on your final tightening pass it stretched then got loose and broke. I hope the rest of your Yr is better for you. Later John

99ssleeper

iTrader: (98)

ahh ic...sorry about that...are you putting any lube on the threads as you torque them?

Yeah, its cold as hell here. I nearly caught hypothermia pulling my cam yesterday

Scalpel

iTrader: (4)

No lube is to be put on new GM TTY bolts.

Inspector12

iTrader: (29)

Ojustracing- Yeah they all started fine and I have a couple of others that I was getting pretty worrie about cause they got felt pretty hard, but they went just fine this one was going I won't say easy caues it was on the final pass but smooth it didn't bind up it seemed to be turning smooth and then BAM broken bolt about an inch into the threads so I am just asking what if anybody else has done in this situation or if they have ever been in this situation etc... Thanks for the info on your breakage. Mine were clean and blown out real good I know no coolant. Maybe a piece of trash stuck, but I highly dought it would cause this who knows it's my problem I'll fix it.

kickassT/A

iTrader: (3)

how goes the battle jeff? you try my suggestion?

code4

iTrader: (30)

Maybe I'm missunderstanding your situation but couldn't you drill a hole in the end of the bolt then use an "ease out" It shouldn't be in any kind of a bind. The bolt is 4 inches down there with head still on correct. So you would have to remove the head to use the "ease out"

Inspector12

iTrader: (29)

Yeah that will be my first try but even with the head off it is like 3.5-4 inches down I don't know of or haven't found an easy out that long yet and drilling the hole that I can't see could be a chore etc... It isn't perfectly flat and if it goes off to one side it will drill through the aluminum first rather than the harder steel etc... So now you see my problem I am going to search for an easy out on Monday and that will be my first try along with a reverse drill bit. Thanks

z-ya

iTrader: (1)

Ya left hand drill and a prayer.

CharlieLed

iTrader: (1)

I bought a TimeSert kit to repair head bolt holes. It comes with a drill and guide to clear out the hole and bring it to the correct diameter for the insert. The insert is steel and once installed is stronger than the aluminum block. This kit is not cheap but the local machine shop (who normally charges $35 to install an insert) did not have the 11M x 2.0 setup that is needed for the LS engines. I would contact the machine shops in your area and see if they have the proper TimeSert or Kent-Moore equipment to make this repair. The dealer usually has the kit but will only do the repair as part of a complete job....$$$$

Inspector12

iTrader: (29)

Thanks a bunch that is the kind of info I was looking for. Where did you purchase your kit from? About how much was it? I have a guy at the dealer who is going to let me borrow it if he can find it? I am just trying to prepare for worst case. Thanks again for the info.

code4

iTrader: (30)

Now I see your delima man this sucks. I wonder if I could drill a cut off piece of stock head bolt perfectly down the center with my drill press. Then you could screw the bolt into your block and use it as a guide to drill into the broken piece.

Cal

iTrader: (1)

Not easy with a drill press, but cake on a lathe. You chuck up the bolt and run the drill bit in with the tail stock. Either way, starting the hole with center drill is the way to do it.

CharlieLed

iTrader: (1)

The insert kit from TimeSert cost me $358 delivered. To buy the same kit from Kent-Moore is $579.
The last block I worked on needed to be welded due to the previous owner's failure to clean out the bolt hole which caused the casing to split; luckily it was the lower left-most head bolt on the right side...so the welder could get to it and repair the crack. Since the hole was now welded at the bottom, the machinist had to drill the hole out so he made a special drill guide to hold the drill bit while he drilled the new hole. You may need a guide like this to drill out your head bolt, I would suggest that you contact the machine shops in your area to see who does this type of work. I was fortunate in that the block was bare and out of the car when I had this done. Good Luck!

ILLWS6

iTrader: (13)

Good Idea IMO.

Inspector12

iTrader: (29)

Thanks charlie! One of my best friends work a at a machine shop so I will call him and see what he can do for me. That is kinda pricey.
Code4- Yeah I appreciate the offer, but like Cal said that is near impossible on a drill press, and besides the stock bolt would offer too much play still I think I am going to have to have a solid peice of stock made to keep the bit from walking all over the place etc...

V-10 Killer

iTrader: (22)

Maybe you could find a piece of stainless steel tubing to slip in the bolt hole and use as a guide. I know drilling and backing something out presents its own problems. Last year I tried that on a bolt on my lawn tractor. Didn't get all the metal shavings out and snapped the easy-out. I sincerely wish you luck, because it's not gonna be easy.

Inspector12

iTrader: (29)

Thanks I have my friend coming over tonight to help me make a guide that will slip in the hole and let me drill strait hope fully I don't think the stainless tubing would be tight enough to keep it from walking. We are talking about a steel dowl to fit down a few inches with a hole in the center to drill it with a reverse bit and see if it comes out. I have my fingers crossed LOL!