Thanks guys. The broken bolts are relatively easy. I bought a good left hand drill set, and I have torches. I ususally heat them up, and start with a 1/8" drill, then go up a size or two, just below the tap/drill size for the hole. 9 times out of 10, using the left had drills, when the 2nd size goes in, it "catches" just as it it coming out the other side, and backs the broken bolt out. I also heat them well, and let them soak with blaster overnight before I do the process. Worst case, I use the correct drill size for the tap. drill it out, and re-tap the hole.
I use a center punch to get the drill started as close to center as possible. One last note for those of you who use "easy outs". You need to be relatively close to the bolt size before you start. One mistake that a lot of people make is using too small a hole and easy out. that is why they break off. Drilling the hole close to the bolt size not only heats up the bolt, but disturbs the threads a bit when it cools. In fact, if you just start to see the sharp edge of the threads, you can usually just clean it out with a tap. Key point is to locate the center of the hole, and use a center punch to keep the 1/8" drill from "walking".
I am really interested in hearing about what to use on the new gaskets, and castings. I am having the castings boiled as we speak, so they will be clean and rust free when go to reassemble.
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