Posted by 4wdtom on September 20, 2016 at 06:53:17 from (96.233.137.93):
In Reply to: Broken Head Bolts posted by Super-H-Mike on September 19, 2016 at 15:36:16:
I like the idea of making a drill guide from the bolt pattern on the head. Drill increasingly larger holes until you see the top of the thread poking through on one side. Even with the drill guide you probably won't be lucky enough to drill the hole in exactly the center so the threads will show on one side first. At this point you can often tap the remaining metal with a punch or chisel and it will give a little. On really stubborn ones I have used a jig saw or even a hacksaw blade ground to fit into the hole and sawed through the threads to provide "give" for the rest of the broken part. I know, you say "saw into the threads"? It is only a narrow cut and usually the thread depth will more than make up for any strength you are removing with the saw cut. On a 7/16 screw I would bet you are going to have 3/4" or more thread depth, twice the thickness of a nut. Usually you can carefully tap the hole deeper too by using plug and bottoming taps and get more thread depth if you feel it necessary. This may help anyway if you feel you have damaged the threads in a serious way in removing the broken part even if you don't use my method of sawing into the threads. Then screw a cap screw into the hole until it lightly bottoms, measure how much it is from the block to under the head, compare with the thickness of the head and adjust so you are not bottoming out the cap screw, you will also be adding the thickness of a head gasket. Give it a 1/16 or so to be sure and you now have more thread engagement than before.
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