advice please

[TonupS2]

Hi guys
I have found that one of the rocker cover bolts (which I thought was just missing) has infact had the head broken off some time past. There is still a short stud protruding but it's too tight to get molgrips in there. It's into the aluminium part of the engine under the fuel rail. I didnt really want to take this aluminium lump off the engine.
Any engineers out there with a cunning plan on how I could remove the stud?

[heightswitch]

TonupS2 said:

Hi guys
I have found that one of the rocker cover bolts (which I thought was just missing) has infact had the head broken off some time past. There is still a short stud protruding but it's too tight to get molgrips in there. It's into the aluminium part of the engine under the fuel rail. I didnt really want to take this aluminium lump off the engine.
Any engineers out there with a cunning plan on how I could remove the stud?

Tap the centre of the sheared bolt with a centre pop. Then buy a good quality dewalt drill bit. Slowly drill down into the centre of the bolt and progressively increase the size of the hole. Then buy some small stud extractors which can be had for relatively low cost to screw anti clockwise into the drilled hole to allow you to remove.

Make sure you drill your hole as near to centre as poss to allow a max hole to be drilled without breaking into the threads of the casting.

N

[hvdweerden]

if everything fails, use heli-coil. did mine some time ago

http://www.helicoil.in/



Han

[Griffinr]

A sharp tap with a hammer to the end of the stud may loosen it enough to remove it if you can find something to grip it with. I sheared off bolt in the thermostat housing, gave it a wack with a hammer and it came out easily with pliers. Maybe I was just lucky.

Rob

[steve j]

Remove the rocker cover, then you`ll have much more access to work on it

[Barkychoc]

It might be a better option to swap out the inlet manifold - if you're going to start drilling you have metal swarf flying around that you need to keep out of the engine plus the pain of making good the threads.
I'm sure someone has a manifold tucked away for some beer tokens?

[TonupS2]

Thanks guys.
Got a tough pair of slim molegrips coming tomorrow (hopefully slim enough) been treating it to liberal doses of penetrating oil. Fingers crossed.
If not it will be drilled and stud remover etc. and then heli-coil if necessary. I will make sure no swarf can fall in the engine Chris. Bloody anoying how a small job escalates though.

[phillpot]

Barkychoc said:

I'm sure someone has a manifold tucked away for some beer tokens?

Sure have

[Gerald-TVR]

phillpot said:

Barkychoc said:

I'm sure someone has a manifold tucked away for some beer tokens?

Sure have

+1

[TonupS2]

Thanks guys all sorted now. The mole grips did their job well and gripped the 5mm of stud sticking out. However it was stuck so solid the 5mm sheared off. Used good quality drills and carefully worked up the diameter until only the bolt material that was in the thread of the hole was left, and that pulled out with a pair of pliers like a spring. I was very lucky. The thread in the hole is perfect, undamaged by the drilling. Thanks for your help.