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I need some advice: back header bolt wouldnt come out. Drilled it out slightly off. Taped it and the bolt screws in about a quarter, maybe a lil more. Should I leave it like it is and use washers? Or what should I do? Thanks In advance!
Do not try to use the hole like it is. The threads will strip out before you could get the bolt tight enough to hold. Find piece of metal tubing that fits into the hole without too much slop. Use it as a drill jig/bushing to keep your drill bit centered on the bolt. Fast fwd to 2:30
Man I tried to weld to that bolt with ez out stud kit and nothing held! So that's why I drilled the bolt, out my problem is it seems like I drilled the bolt slightly off. Could I use a ball die grinder to get the rest of it out?
Research Dorman Part No. 917-142. It uses a jacking bolt that bears against the header flange and presses it against the head. I used one on my ls1 along time ago when I cross threaded a rear exhaust manifold hole installing my headers. I don’t have an exhaust leak - not sure if it’s due to the stiffness of the header flange transfering ample clamping force or the Dorman product, or both, but it works.
Last edited by DUSTYWS6; Mar 9, 2022 at 07:18 PM.
Reason: Added part number
Dusty that Dorman part is pretty slick. I just couldn't bring myself to spend $50 on it. I would remove the broken bolt...that's just me. If you have a broken ez-out in the bolt you will need to use a carbide ball rotary file in a grinder to grind the broken ez-out out of the broken bolt before you can drill the bolt.
Kind of hard to explain, but if you look at the head, there are two threaded holes that are not used. I recall one hole was on each side of the exhaust port, so the bracket spans over the primary. With the bracket secured to the head by the two bolts, there is a threaded hole in the bracket that you put the third screw. As you tighten the screw, it passes through the bracket and makes contact with header flange and presses it against the head. If you look at the head and a picture of the bracket it may make sense. If not, you can PM me your phone number and I can text you a picture.
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Need advice on header issue! 
