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Old 06-07-2014, 11:47 PM   #231
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

OUCH!!!!!! THAT sux BIG time..... Sorry to hear that!
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Old 06-08-2014, 12:42 PM   #232
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

i wish you success.
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Old 06-24-2014, 09:01 PM   #233
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

I need some motivation to keep working on this thing, anyone got any ideas?
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Old 06-24-2014, 09:17 PM   #234
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

I feel your pain
in the past I have used a mig welder and welded nuts to the end of a broken stud, even if it was broken flush you can weld a nut that is the same size as the stud a combination of the heat and a good weld sometimes works good.
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Old 06-24-2014, 10:57 PM   #235
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

I worked in the auto machine shop trade for many years. Repairing broken studs was a daily occurence.
If the head was off, easy to thow it on a bridgport + make sure you get the holes straight. If they are crooked at all, you'll have a hell of a time lining up the manifold.
You have room to work on it-thats a good thing. First center punch the stud -the more perfect you get it will pay off in the end. Start by drilling a small hole-1/8" or so. Then work you way up thru your sizes. Its a lot easier to do 4 or 5 upsizes than try to take it all out at once. Once you get close to final size,I would make up some form of drill fixture to make sure you get the hole right. A piece of metal maybe an inch thick with whatever hole size you use drilled thru it. And have some way to clamp it in place-like off another manifold bolt hole. Your last upsize will hopefully still be in the broken bolt--and not into the head. If the gods are with you, once you get close to the tap drill size, the bolt remnents are thin enough to pick out. I would try to to run a tap down the original holes. Big serts/Time serts are tricky to put in right-and if you mess it up--you are really screwed. You hole is very oversized-and nothing to fall back on after that.
And since the manifold is off, check it for straightness.
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Old 06-24-2014, 10:59 PM   #236
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

Hang in there Porkchop --- Sorry to hear it has gotten complicated. But as I recall, you said in your first post you liked getting your hands dirty and fixing things. Here's your chance to do both. Just try to focus on how much better it will be when you are done with it. Good luck bud.
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Old 06-25-2014, 09:18 AM   #237
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

Wow. Quite an undertaking. Looks like you're handling it with an optimistic attitude.

Just a quick question: Are you flipping off the engine in the pictures above? All I can see is a middle finger. Haha!

Good luck!
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Old 06-25-2014, 11:22 AM   #238
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

Not to be a smarta$$, but what you have there is cake compared to a v8, for the simple fact that you can get at the work easily. I'm a mechanic in the rust belt and just about every ford and dodge truck with a v8 has broken/rusted manifold bolts. With them you have to raise the engine off the mounts, use a 90 degree angle drill, and squeeze your hands in between the head and frame rail just to work on the thing. I only do about 1 a week (that's all the patience I have) so I'm pretty good at doing it. So here's a few suggestions.

I've never had an EZ out work, regardless of the brand. Usually if it came out with an ez out, it would have came out with a vice grips or left handed drill bit.

I've used cobalt drill bits with good success, all the carbide bits seemed to be too brittle to use with anything but a mill. Stay away from your coated hss bits that you can get at the hardware, it might work for the first bolt but the coating will wear off easily, also hardware store bits aren't the best quality in the first place.

If you think it is rusted, heat and penetrating oil will be your best friend. PB blaster is good but I prefer aerokroil. It just seems to work better. If the stud isn't broken flush with the head, get a good visegrips, heat the head up with an acetylene torch, quench the bolt with penetrant, and than turn the stud out with the vice grips. It takes a certain feel to figure out if it's going to come out or snap off. So don't be afraid to heat it up and or quench it multiple times.

If you have a good 220 welder you can try and weld a nut on there, especially the bolts that aren't snapped off flush. It does work but it requires practice and good equipment. I"ve only done it a few times because with the pickups you can't get a welder in there to do it.

If you're going to drill it out, use left handed bits. Making sure the bit is centered is very important, so grind the end of the bolt flat to the head. I then use a 3/16 x 60 single flute uncoated countersink. It has a sharp point and is very good at creating a center. They seem to work better then center drills do or just trying to free hand a regular bit. You can get them at any machine shop, or from here http://www.mcmaster.com/ part # 3285A32 . Then you will use a small bit, and size by size work your way bigger until it screws out via the drill, or you have the whole bolt drilled out.

Any other questions or tips you can pm me.
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Old 06-25-2014, 03:21 PM   #239
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

Awesome "rust belt" engineering!!
Quote:
Originally Posted by Booyah45828
Not to be a smarta$$, but what you have there is cake compared to a v8, for the simple fact that you can get at the work easily. I'm a mechanic in the rust belt and just about every ford and dodge truck with a v8 has broken/rusted manifold bolts. With them you have to raise the engine off the mounts, use a 90 degree angle drill, and squeeze your hands in between the head and frame rail just to work on the thing. I only do about 1 a week (that's all the patience I have) so I'm pretty good at doing it. So here's a few suggestions.

I've never had an EZ out work, regardless of the brand. Usually if it came out with an ez out, it would have came out with a vice grips or left handed drill bit.

I've used cobalt drill bits with good success, all the carbide bits seemed to be too brittle to use with anything but a mill. Stay away from your coated hss bits that you can get at the hardware, it might work for the first bolt but the coating will wear off easily, also hardware store bits aren't the best quality in the first place.

If you think it is rusted, heat and penetrating oil will be your best friend. PB blaster is good but I prefer aerokroil. It just seems to work better. If the stud isn't broken flush with the head, get a good visegrips, heat the head up with an acetylene torch, quench the bolt with penetrant, and than turn the stud out with the vice grips. It takes a certain feel to figure out if it's going to come out or snap off. So don't be afraid to heat it up and or quench it multiple times.

If you have a good 220 welder you can try and weld a nut on there, especially the bolts that aren't snapped off flush. It does work but it requires practice and good equipment. I"ve only done it a few times because with the pickups you can't get a welder in there to do it.

If you're going to drill it out, use left handed bits. Making sure the bit is centered is very important, so grind the end of the bolt flat to the head. I then use a 3/16 x 60 single flute uncoated countersink. It has a sharp point and is very good at creating a center. They seem to work better then center drills do or just trying to free hand a regular bit. You can get them at any machine shop, or from here http://www.mcmaster.com/ part # 3285A32 . Then you will use a small bit, and size by size work your way bigger until it screws out via the drill, or you have the whole bolt drilled out.

Any other questions or tips you can pm me.
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Old 06-25-2014, 04:14 PM   #240
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Re: Smells Like Teen Spirit: Conversion of 1999 Thomas MVP

I don't know if I'd call it engineering, more like trial and error,dumb luck and persistence all rolled together.

Another thing I forgot to add. If you're getting frustrated at it, walk away and do something else until you forget about it. I was doing a dodge once( another shop used the wrong bolt like what you have here) and got so pissed I started throwing tools. Walked away and cooled off and wound up pulling the bolt out in less than 5 minutes. A project like this requires patience, and the first thing to go out the door when you're angry is patience. So keep a cool head.
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