when i bought my 454 it had 2 exhuast manifold bolts broken off flush in the head now that i have the motor pulled and in the process of being rebuilt i figure this is a good time to get them out i tryed to drill them out once but that was taking forever and stoped what is the easiest way to remove them

The two ways I have always used seems to work.. One works if other one dont.

Try easiest one 1st..
Easy outs. They are left twisting drill bits so to speak. You drill a hole in the center of broke bolt, then place the easy out in hole and turn with a wrench/socket. The Easy out grabs/cuts into the sides of hole you drilled and turns the bolt.
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=40349
http://store.summitracing.com/partdetail.asp?autofilter=1&part=WMR%2DW2966&N=700+4294925139+4294925137+4294800483+115&autoview=sku

Here's another type
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=38180

The next option if the easy outs don't work is to weld to the broke bolt. Use a mig welder and weld you a small bead/hump, dot what ever you wanna call it in center of broke bolt.. Then use vise grips on the weld and turn.

Before you do any of that though spray some WD-40, PB blaster, etc on the broke bolt. Also try to drip some 10w30 oil on bolt and see if it will wick its way around the threads. Another thing to try to help losen it is hot wax. Heat the bolt/hole with a small torch, then take a lit candle and drip some hot wax on broke bolt/hole. The wax will make its way down and around the hot threads, then cool off waxing all of the threads.

Exhaust manifold studs are PITA when broken. The only luck I had had with them is to drill out and re-tap when they have been rusted in and heat soaked all those years.

Put some torch to them too and heat them up a little when you easy out them, just be careful not to destroy them in the process.

Or pull the head and take it to a machine shop if its that bad.

Good luck!

Another thing to try that might be a little easier than drilling out the bolt would be to cut a slot in it if there is enough of the original bolt showing. Use a hacksaw to cut a slot, then a flat screwdriver (usually along with heat) to back the bolt out. As with the other suggestions, soak with some type of rust penetrant before you start. Good luck.

Here's a trick I learned from a mechanic friend for removing busted off bolts:
Take a nut that is the same size as the bolt you are trying to remove. Place it over what is left of the bolt or if the bolt is broken off flush place it over the end. Take your MIG welder and fill in the centre of the nut (attaching it to the broken bolt at the same time). Be ready with your wrench (or even an impact if you got big b@lls) because you want to try and remove the bolt while it is still hot from the welding. Good luck!

Here's a trick I learned from a mechanic friend for removing busted off bolts:
Take a nut that is the same size as the bolt you are trying to remove. Place it over what is left of the bolt or if the bolt is broken off flush place it over the end. Take your MIG welder and fill in the centre of the nut (attaching it to the broken bolt at the same time). Be ready with your wrench (or even an impact if you got big b@lls) because you want to try and remove the bolt while it is still hot from the welding. Good luck!

That is exactly how we do it.

First of all, it's not an easy out. It's a screw extactor. There is nothing easy about them and they very seldom get any broken bolt out. LOL!

The VERY best way to get them out is to weld a nut onto them, wait till the color goes out of the nut, and try to work the welded nut tight and loose to work the broken bolt in the threads. I've also dripped candle wax down the threads. It's a lubricant so it helps lube the threads between the bolt and the cylinder head. I've used this method on many a broken bolt (ALL the exhaust manifold bolts broke off on a 2.8L V6 S10 motor that I had to put into a S10 I was selling. Got all the bolts out using the above method.).

First of all, it's not an easy out. It's a screw extactor. There is nothing easy about them and they very seldom get any broken bolt out. LOL!


Ha-ha! A buddy of mine calls them, "easier said then done outs"

not-so-easy-out's

the welding a nut method has allways worked well for me,the heat from the mig will help break it loose,easy outs will work but if you happen to break one of those off in the hole,you might as well forget it as they are impossible to drill out,ask me how I know-lol-good luck-Harvey