my pop's is gonna kill me!!

[430xrider]

Ok here i go i thought it would be nice to get him a header for his 85 250sx''christmas''. So the pipe came in i soaked the header bolts in some w-d 40. thought it would be ok to take it off and snap broke the bottom screw in the head.the top one came out no prob.Need help thanx , chase

[speed20]

you could weld a nut on the bolt (if its not broke flush with the head) or you could get the head hot (where the threads are for the exhaust) and try to get it out.....use vice grips and clamp them on as tight as you can and then some so it doesnt slip! good luck

these are the 2 methods i use and both of them work!

[430xrider]

No the bolt is in the head about the thickness of two quarters ''in the head none sticking out'' i need to buy a bunch of beer get smashed then tell him. :D

[430xrider]

:Beerchug :Beerchug :Beerchug :Beerchug

[Crash104936221]

you could try to warm up the head and use a ez-out you might get lucky

[NOS_350X]

So far with every broken bolt ive had, ive been able to remove them with heat and an ez-out.

[renotrikeguy]

Heat and an EZ Out.. If that doesnt work then the beer wouldnt hurt.

[tecatecrazy]

just tell him you broke it and let him deal with it, just make sure you give him the pipe first :D . good luck

[1985 200s]

Just put the top bolt back in clean up the wd-40 glue the bolt head back in place and give him the pipe. SHHH :D

[honda200sx]

whats ez out???

[jdparsons1]

Drill the bolt out as good as you can and go buy a tap for the next size up bolt. I think those are like 10mm tap it to a 12mm.

[Dirtcrasher]

They are 8mm x 1.25 pitch - The 250SX head has a raised cast boss that is tapped for the studs and it is only about 12mm's in diameter so there would be nothing left if you drilled it out bigger - you can go up 1mm with a helicoil but thats about it.
I could not get mine out of my 250SX head even with oxy/acet - I ended up drilling it as straight as I could possibly imagine and then I just kept increasing the bit size until it was thin enough to get out with a pick. I bought fully threaded stainless steel bolts and made them into studs and used stainless nuts also - shouldn't be a problem agaim. Most important part is the very first hole you drill - if you are off center forget it! I usually use a sharp center punch and whack it and if thats not dead nuts you can angle the center punchand "drive" over the original punch to the center and whack it again for it to be dead nuts and deeper. I start with about a 1/16th drill bit and then a 1/8th. I also keep a spare bit next to me and every few thousandths I stick it it the hole I'm drilling as a guide to let me know if I'm going crooked at all - works very well for me. Good luck!!!

['86X]

Just put the top bolt back in clean up the wd-40 glue the bolt head back in place and give him the pipe. SHHH :D
:D :D :D :D :D :D :D :D :D :D :D :D :D :D

[speed20]

get a drill bit (a size smaller than the threaded part) and drill STRAIGHT into the threaded part as far as you can and then put the drill in reverse and back it out....ive done this on oil pump screws, not sure if it would work on an exhaust bolt but its worth a try!

[Chemical442]

Be careful using an EZ Out. If the tip of THAT breaks off in the siezed bolt you will REALLY be hurting because the metal of the EZ Out is much stronger than the old bolt, making it harder or impossible to drill or tap it out perfectly. I had this happen to me and ended up having to tap it out a little larger resulting in a larger bolt, resulting in having to bore out the hole for the header so it would accept the larger bolt.

PAIN IN THE ASS.

Here's how bad mine was... I tried vice grips, welding to it and backing off, and then eventually grinding it down and doing the EZ Out as noted before... Whatever you do, GOOD LUCK and sorry about your misfortune...

[BP]

For future reference, if you ever have to take them off again? Spray and let them soak, for awhile, and if they are still to tight the best thing is to take a sharp chissel and cut the nuts off. Its alot easier to find new nuts then to try the EZ out way. I had to replace all four in my 350X, I had a local machine shop get them out. It cost me $106.00 for all four, would have been much easier and cheaper to cut the nuts off.

BP

[430xrider]

Yeah today when he woke me up to go to work ''at 3in the am''I handed him the pipe said hope you like your christmas present and oh yeah dad i broke the bottom stud off in the head then i ran to my truck and went to work. I aint seen hem yet. ;) .I relly dont want to see him hes gonna be nuts :twisted: . Thank god im at school tell 9 hopefully he'll be in bed.Can i ask yall a question i might need to borrow someones couch.''hopefullycloseto vegas''.! late,chase

[Tri-Z Pilot]

Nah, he'll get over it, believe me, there is a lot worse things than a broken head stud, A Lot Worse!!!

['86X]

get a drill bit (a size smaller than the threaded part) and drill STRAIGHT into the threaded part as far as you can and then put the drill in reverse and back it out....ive done this on oil pump screws, not sure if it would work on an exhaust bolt but its worth a try!

No way, no how will this work! If the bolt is siezed so bad that it broke off, what makes you think that a drill bit will walk it right out?? If it was a left hand bit and it wasn't siezed, MAYBE, otherwise it won't happen. Centerpunch, drill with good bits in steps to the largest size possible and try a ez-out. Heat from a torch will help in addition to the above.

[Ace Mon]

Youre dead !

[Tri-Z Pilot]

Hey 430x, are you dead yet? You havent posted in a while. LOL!

[84250r]

Heat and an EZ Out.. If that doesnt work then the beer wouldnt hurt.


:D :D :D :D Lets say LOTS of beer.

[350XXX]

left hand drill bits usually dont work in a hand drill because they walk worse than right hand bits, and it would have to be a machine length bit so it wont break. i have a whole set of these and havent used used them in 5 years due to a better way of doing things. they sometimes work, but usually only on SMALL bolts.

[speed20]

broke off flush.....ehhh....i was thinking about another idea.......if it wasnt broke off exactly flush you would cut a line in it with a dremel or something and put a flathead screw driver in there and heat the threads in the exhaust up and try that....but anyway...good luck!

[430xrider]

Not dead yet he just said im a puss for runnin from him we got it fixed and he likes the pipe so thanx for all the help

[Crash104936221]

congrats on fixing the problem what method worked?

Joe

[430xrider]

Took a drill and tap and kept switchin drill bits