Screwed: Broken bolt extractor

JDM GT Four, ST185RC and ST205.

Re: Screwed: Broken bolt extractor

Postby toayoztan » Thu Aug 02, 2012 8:57 pm

Just make sure the manifold mating surface isn't warped either before putting it back on, and use new gaskets if necessary.

That one lower stud alone should be sufficient, as the earlier models and even aftermarket manifolds don't use the 9 stud setup often.

Bryan
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Re: Screwed: Broken bolt extractor

Postby psipwrd » Fri Aug 03, 2012 3:56 am

Thanks, I bought a used manifold and it arrived yesterday. Mine wasn't warped by comparison so I reused it with a new gasket. The turbo, manifold and downpipe are all together waiting for downpipe gasket. I'm hoping to have her running this weekend!
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Re: Screwed: Broken bolt extractor

Postby psipwrd » Sun Aug 05, 2012 6:08 pm

And now the rant!

As I was torquing down the exhaust manifold, a third stud stripped. I took everything apart again and attempted to tap that hole but I couldn't keep it centered with the ratchet. So I ran out and bought a $44 euro tap and die kit just for the tool that holds the tap. Got it tapped and perma-coil installed. YESSS! Went to torque everything down again and the two middle bottom studs stripped! :bangshead:

It's like the block is literally rotting while I'm working on it.

I am running out of patience. I'm torn between

1. putting it together and drop it off for repairs
2. start over, order another perma-coil kit and studs
3. sell it

[/rant]
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Re: Screwed: Broken bolt extractor

Postby toayoztan » Sun Aug 05, 2012 6:24 pm

What's stripping...the threads in the head (it's not the block, but I'm sure you knew that, but were just ranting :D ), or the actual threads on the studs where the nut goes on?

At this point, you might want to think about just removing all the studs, chasing them down with a tap to clean the threads, and putting in fresh studs.

If it seems like all your threads in the holes are just "rotting" away and that's causing you the issues, then you might want to think about putting permacoils in all of them...this allows you to go bigger to get fresh threads for the coils, and the coils of course will be strong and fresh for the studs.

(of course, don't redo the ones you've already done)

Bryan
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Re: Screwed: Broken bolt extractor

Postby Fox 21 Alpha » Sun Aug 05, 2012 6:36 pm

That's horrible, if it really seems to be going that bad might just be best to take it to a machine shop.

And my last ditch solution for any broken or seized bolt was to quick a long as metal stick welded on to whatever you have left. Basically makes a permanent breaker bar....
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Re: Screwed: Broken bolt extractor

Postby psipwrd » Sun Aug 05, 2012 7:47 pm

This is what it's doing...

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That's coming out on the stud threads after it strips. That makes me paranoid about the permacoils I just installed. I don't know if that's the HEAD or an old helicoil/permacoil kit. That's what makes me want to take it to a shop.
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Re: Screwed: Broken bolt extractor

Postby bridge47 » Mon Aug 06, 2012 12:01 am

Regarding broken extractors. Use the hardness in your favor. I've had success using a pin punch and small sledge to break them into pieces which you can then pick out. Use safety glasses and resharpen the pin punch on a grinder every few blows.

If the threads are messed up you can always tap it to 1/2 x 13. 1/2inch is close to 13mm which is slightly bigger than the 12mm hole you have.
Yet another black 93 ST185.....

Facts are stubborn things.
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Re: Screwed: Broken bolt extractor

Postby psipwrd » Tue Aug 07, 2012 3:38 pm

Thanks, I'll try that whenever I feel ready to tackle this beast again.
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Re: Screwed: Broken bolt extractor

Postby psipwrd » Sun Aug 12, 2012 6:31 am

Thanks for all the input guys! I got her put back together yesterday and drove her for a few hrs last night. The downpipe must've been short because the exhaust (heat shield just before the flex section) rubbed on the drive shaft when I was done. I bent the heat shield and no more rubbing. She's running strong, boosting up to psi w/no issues so far! :D
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