aluminum head screw up drilling broken stud

[chpr1972]

While drilling a broken bolt out I went to far and got into the water jacket on the exhaust bolt next to the temperature sending unit! It is a 1/8 " hole at end of the bolt. what is the best way to fix this. There is no room to weld it shut from where it is. I am thinking maybe clean it up with brake clean and using JB Weld. Use old #2 [ #3? ] Permatex on the exhaust bolt Since this is a stock daily driver 2003 Suburban it will probably never come apart again. It is a 5.3 motor.

[raustinss]

oh boy .....you could try jb weld if you know its not coming apart again .....otherwise id say , whats a used head cost

[Kenova]

Thread the hole for a pipe plug or set screw?

Ken

[WOLF1732]

don't stress. Put silicon on the bolt and in the hole when you put it back in.

[dontlifttoshift]

Mopar big blocks and others have exhaust bolts in the water jackets. I have seen them sealed with RTV and pipe dope in the past and have used both with success.

We had one that problematic, would not seal. An old machinist told me to melt some solder onto the bolt threads, starting about 3 threads from the end and covering about three threads completely. I laughed and figured I had nothing to lose and sonofabitch it worked.......old guys are smart.

I would skip the JB weld, seal the threads, and call it a day.

[chpr1972]

silicone on bolt. no problems yet! thanks for feed back