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Drilling broken exhaust bolts

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Old Oct 11, 2023 | 08:47 PM
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Default Drilling broken exhaust bolts

So to begin, I’ve already committed to drilling the 3/12 exhaust bolts that broke and installing a helicoil .
All were snapped too deep to weld. I’ve tried a HSS, Cobalt, dremel, LH Drill bits and I have yet to make it hardly past where the bolt snapped.

Does anyone have any ideas?
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Old Oct 12, 2023 | 05:38 AM
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They have loctite on them from the factory. Heat them up with a torch and try again.
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Old Oct 12, 2023 | 12:58 PM
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They're easy to weld even when really far down in the hole. Just build it up till you can weld a nut to it
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Old Oct 12, 2023 | 01:08 PM
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Your options are welding a nut to it (very effective) or using carbide drill bits in a mill/drill press with fixtures.
Dont even try to drill them by hand, the bolts are hardened and your bit will want to shoot off into the soft aluminum.
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Old Oct 12, 2023 | 03:39 PM
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If you really want to drill them and they are deep in there, I have a way to center drill them. Take a 8x1.25 bolt and cut it down to where there are 2-3 threads showing then center drill it with a small bit. Then thread it in the hole and run that same bit through to center drill the bolt. I'll post a pic of the one I made in a second
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Old Oct 12, 2023 | 03:44 PM
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The bolt I made for center drilling them

But again I would weld them.
Best scenario if you still choose to drill is to use the mayhew pro screw extractor kit if you still decide to drill them





Last edited by 00pooterSS; Oct 12, 2023 at 04:03 PM.
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Old Oct 12, 2023 | 07:16 PM
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You can use a steel sleeve as a bushing when drilling into an aluminum hole, such as this. Cut up a pushrod and stick it down into the hole when drilling to keep the drill bit off the aluminum threads. Be creative and look at other tubing types/sizes to put in your toolbox, for crap just like this.
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Old Oct 12, 2023 | 07:41 PM
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https://www.motionraceworks.com/prod...-drill-fixture
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Old Oct 12, 2023 | 07:59 PM
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That’s a super nice fixture.
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Old Oct 12, 2023 | 09:58 PM
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Taking a nut and welding is the easiest way to remove the sheared bolt from an aluminum head.
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