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Old 02-07-2017, 05:49 PM   #21
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Join Date: Nov 2015
Location: Midwest
Posts: 2,573
Year: 2003
Coachwork: BlueBird
Chassis: TC2000
Engine: 5.9L Cummins
Rated Cap: '00
EDM, tap disintegrator, kroil, heat. Not in that order.

no bueno.

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Old 02-07-2017, 06:46 PM   #22
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Join Date: Feb 2012
Location: Salt Lake City Utah
Posts: 1,580
Year: 2000
Chassis: Blue Bird
Engine: ISC 8.3
Sorry you haven't been able to get that bolt out yet. I had an exhaust stud that broke in a Honda Nighthawk 250 head. Tried to use an extractor and broke that off too... in the end I pulled the head off and had a machine shop fix my mess. IIRC EDM was their choice method.

I don't even own any extractors anymore. It just seems safer: if the thing is so stuck that it broke, then an extractor will break in there too! I've done the weld-a-nut method several times, and although it often takes a few tries to get good penetration into the broken bolt/stud, it has served me well. It's much less scary to do that on an aluminum part rather than iron: I don't worry about welding the steel nut and bolt to the block!
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Old 02-20-2017, 03:40 PM   #23
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Join Date: Apr 2013
Location: Colorado
Posts: 1,598
Year: 1993
Coachwork: bluebird
Engine: 5.9 Cummins, Allison AT1545
Rated Cap: 2
wow, that edm is too cool. with all that i spent on taps,extractor sets, drill bits, mil bits, and dremel bits, i was a 1/4 way to the cost of one of those EDMs. still that would require the removal of the head, so i've just stayed at it, trying not to bugger it worse.

this weekend i broke through the other side and was pretty excited.

it's taken me a month of serious chipping at the bolt to clear it out.



then today i was able to pick up another tap - 10mm, same as the original hole. it looks like half the threads survived.




anybody know if half threads are sufficient to hold? its supposed to be torqued to 32 ft/lbs. its the last bolt to tighten in sequence of torquing the manifold.

honestly, i think the upper surface of the hole is thread all the way. the camera angle is the same angle as my drill access. so what threads you dont see are probably there.
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Old 03-01-2017, 05:37 PM   #24
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Join Date: Apr 2013
Location: Colorado
Posts: 1,598
Year: 1993
Coachwork: bluebird
Engine: 5.9 Cummins, Allison AT1545
Rated Cap: 2
i got some bling installed today. almost anyway. i need 2 more wires. but i got the gauges put in and hooked up as much as i could. still need another trip to the hardware store.
new transmission temperature, EGT temp, and tachometer!
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