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| How to remove broken thermostat housing bolt remnants https://www.ausmini.com/forums/viewtopic.php?f=5&t=56585 |
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| Author: | mini7boy [ Mon Aug 31, 2009 12:48 am ] |
| Post subject: | How to remove broken thermostat housing bolt remnants |
While removing the thermostat housing and sandwich plate on a stored core engine, I was surprised how easily one of the bolts broke. The bolt has broken below the head surface. Is helicoil a viable fix for this problem once the bolt remnants are removed through drilling or milling? Is the bolt of such hard material that its removal requires super hard material in the drill bit or end mill? I have installed helicoils in aluminum very easily. How easy is it to install them in cast iron? Do you use different helicoil kits for cast iron? Whomever installed the bolts last time obviously didn't use any type of anti-seize or otherwise this problem could have been prevented. Just goes to show that we should all use ant-seize in all blind holes where corrosion is possible(like rear subframe trunnion bolt holes in the shell). Other places where anti-seize can be used to prevent seized bolts are: caliper bolts, bleeder screws, plumbing fitting holes in calipers and block. If this had been an expensive prepared head(Longman, Swiftune, Calver, MED,etc.), broken thermostat bolts could be a major teardrop that could easily have been prevented with anti-seize. Carpe diem(seize the day). Use anti-seize or be seized. Don't have a seizure, use antiseize. |
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| Author: | drmini in aust [ Mon Aug 31, 2009 6:44 am ] |
| Post subject: | |
These studs or bolts are only grade 5, nothing special. I mark and drill them ON CENTRE, then screw a 5/16/UNC tap in to remove the remnants. It's not too hard, easier than removing S/S studs from alloy outboard motors... 
I like using bolts, with Loctite #3 gasket cement on the threads. it keeps the water out... Bolts are better because they don't seize solid in the alloy thermo housing like studs do. |
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| Author: | 850man [ Mon Aug 31, 2009 4:46 pm ] |
| Post subject: | |
A good way to remove broken bolts/studs that i have used for many years is to weld a nut on to the top of the broken part with a mig welder. You pool the weld up inside the nut untill flush with the top and while its all still hot use a spanner to remove the stud. Works very well on broken head studs, exhaust studs & thermostat housing bolts/studs. |
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| Author: | mini7boy [ Mon Aug 31, 2009 10:24 pm ] |
| Post subject: | |
thanks for the tips ! |
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| Author: | Mick [ Mon Aug 31, 2009 10:34 pm ] |
| Post subject: | Re: How to remove broken thermostat housing bolt remnants |
mini7boy wrote: I have installed helicoils in aluminum very easily. How easy is it to install them in cast iron? Do you use different helicoil kits for cast iron? Same method, same kits, no problem to fit. |
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| Author: | Mick [ Mon Aug 31, 2009 10:35 pm ] |
| Post subject: | |
850man wrote: A good way to remove broken bolts/studs that i have used for many years is to weld a nut on to the top of the broken part with a mig welder. You pool the weld up inside the nut untill flush with the top and while its all still hot use a spanner to remove the stud. Works very well on broken head studs, exhaust studs & thermostat housing bolts/studs.
Now thats a nice solution! Beats the hell out of drilling and busting ezyouts! |
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| Author: | drmini in aust [ Mon Aug 31, 2009 10:40 pm ] |
| Post subject: | |
Ezyouts are a waste of time in this application. If the stud is so tight that it broke when undoing, no way will an ezyout remove it. It'll probably break first, then you have a REAL problem, as they are hard as buggery. 
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| Author: | TheMiniMan [ Mon Aug 31, 2009 10:54 pm ] |
| Post subject: | |
I Love Copper Coat 
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| Author: | mini7boy [ Tue Sep 01, 2009 9:39 am ] |
| Post subject: | |
probably Copaslip by a different name. |
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| Author: | Maxi23 [ Tue Sep 01, 2009 1:57 pm ] |
| Post subject: | |
Caltex call it Kopr Kote if you see it for sale in a servo. Magic stuff
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| Author: | clubmn [ Tue Sep 01, 2009 2:08 pm ] |
| Post subject: | jae |
[quote="drmini in aust"]These studs or bolts are only grade 5, It's not too hard, easier than removing S/S studs from alloy outboard motorsquote] Or jet skiis which is what i spent my weekend doing. |
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