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/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> exhaust screw-am i in trouble? /cgi-bin/YaBB.pl?num=1342022701 Message started by highlander10 on 07/11/12 at 09:04:57 |
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Title: exhaust screw-am i in trouble? Post by highlander10 on 07/11/12 at 09:04:57 Hi, i took the exhaust off to wrap it and the right screw broke. i tried to extract but now i have a broken screw and a hole in it. What can i do? I am thinking of pulling the engine down. Open to all proposals |
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Title: Re: exhaust screw-am i in trouble? Post by highlander10 on 07/11/12 at 09:05:30 one more |
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Title: Re: exhaust screw-am i in trouble? Post by 360k+ on 07/11/12 at 09:27:19 And you've already tried an easy out tool? |
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Title: Re: exhaust screw-am i in trouble? Post by Paraquat on 07/11/12 at 09:45:45 Bigger easy out. If I recall those are m8x1.25. Since you're already off center drill it out with a .250 or .265 drill and it should penetrate one wall causing the screw to collapse which will make it easier to extract. Then just retap it. --Steve |
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Title: Re: exhaust screw-am i in trouble? Post by highlander10 on 07/11/12 at 14:13:55 I tried to extract the screw, nothing. then i tried to make new threads and the tool broke inside but just a part of it like smthg less than 1cm...i am thinking of drilling till everything is out. It is so hard to make new threads cause all these thread tools look soft in comparison with the engine's metal. Is this a dangerous let's say area for the engine? can i damage the cylinder? |
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Title: Re: exhaust screw-am i in trouble? Post by Serowbot on 07/11/12 at 14:56:26 It looks like there is some depth there,.. is there?... Can you find a common blade screwdriver that's just tight in the hole?... then, tap it in tight with a mallet and try to unscrew... plenty of penetrant oil... :-?... |
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Title: Re: exhaust screw-am i in trouble? Post by splash07 on 07/11/12 at 15:03:14 Some useful info here. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1341436398/0 |
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Title: Re: exhaust screw-am i in trouble? Post by 360k+ on 07/11/12 at 15:36:01 6D6C626D69646B6160773435050 wrote:
Tools like taps and easy outs are VERY hard steel, but also brittle (they don't bend), so you have to work with them more gingerly than regular nuts and bolts. Use plenty of oil or anti seize, and twist just a little at a time before backing the tool out to clear the filings. In any case, I think these tools are much harder than the head itself, or even the bolt you're trying to remove. |
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Title: Re: exhaust screw-am i in trouble? Post by 87 savage on 07/11/12 at 18:26:56 6B6A646B6F626D6766713233030 wrote:
Is that a crack and a bead of weld in the head? Anyhow, see if you cant drill it out just a wee bit wider (carefully) so as to get as close to the threads as possible without messing up the threads. Then take a small punch with a nice flat edge placed against the edge of the bolt standing above the surface of the head and give it a sharp tap with a hammer to collapse the threads of the bolt in on themselves. This works well. Might come out in pieces but then you can clean up the threads in the head with a clean oiled tap. The key is to get the walls of the bolt as thin as possible without damaging the threads in the head. Take your time, It will come out. |
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Title: Re: exhaust screw-am i in trouble? Post by justin_o_guy2 on 07/11/12 at 18:30:47 I would get my little soldering torch ( $10.00 at Lowes), fill it with butane & remove the soldering tip & heat that thing up good, then, Id take my squirt bottle ( set to pump a stream) & squirt Ice Water in the hole youve drilled, then Id put a penetrating oil on it & let it sit. I wouldnt stick an eze out in it yet,.They have to spread the dutchman to bite it,,YOuve got stuff sticking up I think.. Id work at it with alternating heat & cold water & oil, then Id take a pin punch & stick down to the bottom & give it a few quick smacks with a lite hammer. Ill bet you can cut a groove across it ( IF ya do it so you make square shoulders) & back it out with vise grips on a screwdriver,, Or maybe grind a bolt down to go in the hole & JB weld it,,If it goes deep enough & you get enough surface area covered, it otta bring it out, Antisieze is your friend, use it going back together, & FWIW, you could spend hours messin with it doin it my way,, or just a minute or so with an eze out, OR, the eze out could cause you great pain,, I have some, I even have some tungsten carbide ones, I guess theyre about the best Ive seen, & when they work out,, theyre the greatest! Ohhh, but when they dont,, |
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Title: Re: exhaust screw-am i in trouble? Post by Dave on 07/11/12 at 18:35:59 If the other methods don't work....and you have a Dremel tool, you can slowly grind away on the bolt until it is very thin. I have done this and ground until you can just break through the bolt - then use an ice pick or sharp punch to carefully pick out the remains of the bolt. It takes time - but not as long as it would to break the engine down. Even if you do brea the engine down.....you still have a broken bolt stuck in the cylinder! |
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Title: Re: exhaust screw-am i in trouble? Post by Trippah on 07/11/12 at 20:48:17 As mentioned in the referred to post, look into EDM, older machine shops should be able to provide the service. Once an easy-out has broken off, you are trying to drill through hardend metal..difficult to do. |
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Title: Re: exhaust screw-am i in trouble? Post by justin_o_guy2 on 07/11/12 at 21:50:41 1D3B2039392821490 wrote:
Once an easy-out has broken off, you are trying to drill through hardend metal..difficult to do.[/quote] Which is why I go to great lengths to avoid putting an eze out in a dutchman, |
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Title: Re: exhaust screw-am i in trouble? Post by highlander10 on 07/12/12 at 15:04:42 today i decided to pull the motor down and tomorrow i'll bring to a local workshop that is open to public for such works. there is a guy who gives courses about motor repairs and so on and promised to help. Thanks n i'll let you know |
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Title: Re: exhaust screw-am i in trouble? Post by highlander10 on 07/19/12 at 10:44:27 a week or so later... the tap is still there and i spend 20euros in different dremel tools trying to dig around the tap so as to pull it out and then refill the hole with aluminium in liquid form. any other suggestions. I include a recent photo. Greetz savages |
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Title: Re: exhaust screw-am i in trouble? Post by ralfyguy on 07/19/12 at 11:01:06 Did you buy one of those carbide drill bits? Carbide is harder than HSS and you should be able to drill a hole in the middle and try to mill it out from there. Or maybe give it another shot at extraction once you drilled that hole. It's gonna be tedious, but should be doable. |
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Title: Re: exhaust screw-am i in trouble? Post by RidgeRunner13 on 07/19/12 at 11:01:20 Take it to a machine shop or welder & have them weld a nut to the stud. I've done this many times with sucess. The heat from welding usually helps with getting the broken stud out, too. 8-) |
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Title: Re: exhaust screw-am i in trouble? Post by ralfyguy on 07/19/12 at 11:09:50 0D363B383A0D2A31313A2D6E6C5F0 wrote:
That is a better idea even. Set the nut centered on the broken stud and get a tack weld right through the middle. If the weld is good enough, it should come right out. |
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Title: Re: exhaust screw-am i in trouble? Post by RidgeRunner13 on 07/19/12 at 11:14:57 4A59545E415F4D41380 wrote:
That is a better idea even. Set the nut centered on the broken stud and get a tack weld right through the middle. If the weld is good enough, it should come right out. [/quote] Exactly right! And if it breaks off you can usualy just get another nut & try again. I've used this technique to get broken exhaust bolts out of heads. Sometimes it was easier to get a welder to it than a drill. ;D |
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Title: Re: exhaust screw-am i in trouble? Post by Dave on 07/19/12 at 13:43:55 5B5A545B5F525D5756410203330 wrote:
If the welding technique does not work, and you run out of options - then I still believe the dremel is your best bet. It is time consuming and will probably take and hour or two....along with a handful of grinding bits. I have used this method and it does work. The common burrs won't work - you must get a diamond bit or the chainsaw ones. Not sure which color or size would work best - but below is a link to what the look like. I ground out a similar stud on a lawnmower block using this method. http://www.amazon.com/Dremel-454-Grinding-Stone-16/dp/B000LNJX1I/ref=sr_1_11?ie=UTF8&qid=1342729057&sr=8-11&keywords=dremel+chainsaw |
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Title: Re: exhaust screw-am i in trouble? Post by highlander10 on 07/24/12 at 05:29:39 two weeks later! I did it. the tap and the screw are past! Now the story goes like this. The outer half of the hole has diameter of 8mm and the rest half is as it used to. I need new threads for sure but which solution is the strongest? first is as they told me Helicoil that i put together with lock tite after i tap with tap of 10mm and the other one is that i fill the hole with liquid aluminium and hardener and then tap new threads over there. Open again to all suggestions |
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Title: Re: exhaust screw-am i in trouble? Post by highlander10 on 07/24/12 at 05:31:57 and of course the picture |
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Title: Re: exhaust screw-am i in trouble? Post by Paraquat on 07/24/12 at 06:35:16 A helicoil could work but usually if it gets that bad I like to use a keensert/timesert. http://www.mcmaster.com/#key-locking-threaded-inserts/=ijmjo0 --Steve |
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Title: Re: exhaust screw-am i in trouble? Post by ralfyguy on 07/24/12 at 11:13:30 If the threads isn't stripped all the way out, tap it with a 5/16 standard which is about identical in diameter as an M8, but has a more coarse thread and you basically just cut a new thread over the old one. Then use a 5/16 x1 bolt. |
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