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Old 05-21-2014, 11:06 PM   #221
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

I work in the airline industry & we have found using easy outs expands the bolts & causes more problems with the easy out breaking so we usally weld a bolt onto the broken bolt & remove that way
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Old 05-21-2014, 11:09 PM   #222
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

Quote:
Originally Posted by allwthrrider
I work in the airline industry & we have found using easy outs expands the bolts & causes more problems with the easy out breaking so we usally weld a bolt onto the broken bolt & remove that way
I should add, we have very very good welders, people & machines
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Old 05-22-2014, 09:59 AM   #223
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

you could try and use PB blaster and reverse drill bits when you drill it out. it might unscrew when you are drilling it
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Old 05-22-2014, 10:04 PM   #224
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

i tried the reverse drill bit method when i had a bolt broken off in th block on my jeep. worse that can happen is that you end up drilling through the bolt like you were planning on doing anyway.
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Old 05-26-2014, 08:53 PM   #225
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

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Originally Posted by porkchopsandwiches
My thoughts exactly. I had them set to blue on a lower brightness while driving at night which caused no glare issues and put out a lot of light without being distracting. We slept with it red at night, just like a 1940s naval ship I slept on in elementary school (not sure if they still use that today or not). I think they do that to keep your night vision while still having enough light to see.
Just a little note: Today's night vision goggles (NVGs) are extremely sensitive to red light, so the military has adopted a special frequency of blue-green light that is nearly invisible to modern NVGs. As it turns out, because of the way red light focuses on the retina, humans can see better with other wavelengths at lower amplitudes. In other words, you can use a lower wattage blue-green bulb to see and read than you would need if using a red bulb.

In a previous life I was an Army pilot and everything in the cockpit was blue-green and practically invisible to the goggles we used for night flight (old-style red lights would shut down the goggles, even at very low levels). To see the instruments or maps, we would just look under the goggles. What was really cool was when ground personnel would use infrared light-sticks to illuminate a landing zone. Through the goggles, it was plain as day, but without them, it was pitch black.
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Old 06-05-2014, 05:38 PM   #226
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

More on the engine repair saga.

I stopped putting off the repair and dug in.



Starting off with good vibes.

Removed the alternator, serp belt, alt bracket, upper coolant hose, coolant bleed hose, and a few other things that were in the way. I started removing bolts when I found out one was broken off and missing, on the cylinder that was leaking exhaust. So I removed more and it turned out 4 more were snapped and just sitting in the manifold! Then 3 more snapped when I gave them the slightest twist of a wrench. This is after sitting in a week with PB Blaster and tapping with a hammer to break rust loose.

So I finally break / remove all the bolts and wrestle the turbo and manifold out. The bolts to the turbo are such that you can't easily remove them while it is in the engine bay, so I took it out as a unit.















So 5 bolts came out okay, 6 were snapped flush with the head and one was snapped at the head of the bolt. However, I realized something wasnt right with 3 of the bolts:



Hard to tell from this pic but someone used an angle grinder to shave down this bolt. It is evident in looking at the correct one that somebydy just grabbed whatever bolts and trimmed them down to get them to fit, potentially overtightening them which fatigued them and caused them to snap. OR the thing overheated a lot and caused them to snap. It was evident they were snapped a while (rust heavily on the broken surface) so it isn't my doing

Also, the bolts on the turbo oil drain flange were mismatched, one was covered in anti-sieze and one was rusty as hell. So someone got in here and botched the sh!t out of this job. So I have on order:

12 new manifold bolts
6 new exhaust gaskets
1 new turbo to manifold gasket
o rings and gaskets for turbo oil feed / drain
new turbo oil feed line (very rusty, looks like a pinhole leak could start any second)
Oil feed line flange bolts
Turbo to manifold locknuts
and some other hardware...to the tune of $300. Yay. But at least I will be doing it right.

I brought the manifold to a machine shop today to be planed flat and sandblasted. I know it will rust again but it was just dropping chunks of sh!t everywhere it was so rusty.

The fun step will be drilling out all 6 or so snapped off bolt ends, attemoting to use a fluted screw extractor, it breaking and me drilling them out, attempting to tap the threads, failing, and drilling it out and using a helicoil or timesert. The rest of reassembly beyond that step should be easy.

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Old 06-06-2014, 12:07 PM   #227
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

Oh boy, you've stepped in it now!

Well, I suppose it needed to be done...hang in there man!
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Old 06-06-2014, 08:36 PM   #228
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

Hey I will pay you $305.00 to pull and re-do mine. See you would make a profit.
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Old 06-06-2014, 10:20 PM   #229
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

If the second one is easier than the first then the price should only be $295
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Old 06-07-2014, 09:57 PM   #230
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

You guys are hilarious. William, if you need this done i'll do it for cheaper because HOPEFULLY your bolts aren't broken.

Turns out the reason WHY the bolts are broken is because someone who worked on it last was too much of a cheap **** to buy the correct bolts. They took bolts that were longer, presumably not even metric, and cut them down with an angle grinder, didn't bother to shape the ends, and just cross-threaded them in there. So three that were like that came out ok, but 6 snapped. So someones cheapassery is causing me massive amounts of trouble and expense. Thanks, asshole who did this.

I have gotten zero of the broken bolts out and broken 2 easy-outs. So no more of them. The next approach is to drill out the rest, and buy carbide bits for the ones with easy outs in them, and buy these things called Timeserts. They look like this:



Basically a solid version of a helicoil, a more permanent and stronger solution. So you drill out the old bolt and threads a size or 2 larger, tap larger threads, screw this in and then put the regular M10x1.5 bolt in. That is, if I can get the hole drilled / tapped straight and square.

Wish me luck with this so I can get this heap back on the road. So much for that summer road trip!
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