Broken header bolts.

[Number1]

What to use to remove broken header bolts? I heard welding a nut to it but other suggestions please.

[Z06vet]

If its broken off close to flush with the surrounding surface, welding a nut on to it has worked best for me. On the ones broken off deeper into the threads I have used a quality drill bit and an easy out. It takes patience & precision to do it without screwing the threads up. Insert the drill bit into one of the other empty theaded bolt holes & put a piece of tape on the bit to mark the depth. That way you will not drill too far & go into the head. If its possible to centerpunch the broken bolt it will make life easier drilling into it. If the bolt is broken at an angle it AND is deep inside it will not be fun. I would rather remove the head & take it to machine shop at that point. Have a pic of the broken stud?
Scott

[jlcustomz]

You didn't mention whether cast iron or aluminum heads, but I'll guess cast iron. If you still have a stud sticking out you could try just gripping with a good set of grip pliars after a little penetrating lube soak. I'd also tap with a hammer first to shock the threads.
With any stuck fastner as a general rule, you can always tighten first to help break the binds of the threads without stripping as much on the material used to reverse fastner.

For broken off header bolts in the past ,I generally carefully center punch & drill first with a left handed 1/4" bit with a 90 degree angle drill if still on a vehicle. Have rented one in the past when I didn't have. What happens when drilling is between skill & just how stuck the threads are. If the threads are willing , the left hand drill bit may remove it. If not then I proceed either to an easy out or drill larger hole first. Have completely drilled out to the needed drill bit to tap 3/8" threads & retapped before. I never got so off center as to have to drill oversize & used a thread repair insert , so try to be careful & get it drilled right when drilling.

Those little combo drill/ screw extractors you can get at the homestores may work of your threads aren't too stuck, they drill left hand.

[Z06vet]

I guessed aluminum since we are in the LSX forum. Some early 99 LQ4s did have iron heads though.

[Number1]

They are aluminum from an 2001 5.3 vortec motor.

[SShep71]

http://www.youtube.com/watch?v=ffR2pGVGHbg

Jody explains it really well. I have used the technique several times with no problem before. If you were close to me I would just tell you to bring it over and I would do it for you.

[garys 68]

Drill it all the way through, use an easy out. Both my LS motors had broken rear drivers side exhaust bolts.

[renegade6]

I used the welding method. I started with a washer so it was easier to get the wire in there to start a bead, built it up and then welded a not on that. It was almost easy enough to remove by hand. I started with a reverse twist drill bit but, limited on space and the bolt was hardened from all of the heating and cooling cycles.

[andrewb70]

http://www.youtube.com/watch?v=ffR2pGVGHbg

Jody explains it really well. I have used the technique several times with no problem before. If you were close to me I would just tell you to bring it over and I would do it for you.

Just watched the video. totally awesome!

Andrew

[joshtownsend]

plasma cutter..takes 5 sec..