90hp broken bolts

[markoc85]

Two of the bolts broke off when I removed my exhaust cover today to replace the gaskets.

As you can see from the photo both have stubs poking out. I can get vice grips on each of them but they just slip on the stub when I twist.

Does anyone have a good recipe for getting broken bolts out without drilling?

I've already tried expletives and screaming as loud as I can, would beating my wife help? Just kidding! Any help much appreciated.

 

[oldrudedude]

Re: 90hp broken bolts

Put the vise grip securely onto the stud. Heat the housing around the stud with a propane torch while working the stud. The object is to get the housing to swell up more than the stud. It may help to squirt or drip a little cold water on the stud to contract it away from the housing. This method has worked for me. Keep heating the housing and working the stud until it moves.

 

[Bob_VT]

Re: 90hp broken bolts

Welcome to iboats. Swearing at broken bolts helps....keeps your blood pressure down

I would also use a torch (propane) and some pb buster. I would lightly heat the area and apply the penetrating fluid and walk away for at least an hour.

Re-heat the area and then try the vice grips.

The real secret is Patience! If it does not wok let it soak overnight with pb buster.

Remember those are "should be" stainless steel bolts and re certain to get stainless steel ones to replace them with

 

[kenmyfam]

Re: 90hp broken bolts

As Bob with one thing to add. After soaking, try to work the bolt slightly in both directions till you get some movement.

Do not beat the wife !!!!! you need someone to bring you a beer while you are working.

 

[tboydva]

Re: 90hp broken bolts

My brother-in-law taught me a trick which has worked every time (for me). Heat up the area around the bolt while holding a candle on the exposed bolt shaft. The heat will draw the wax into the threads. Move it back and forth (as others have said). It's worked for me...

 

[robert graham]

Re: 90hp broken bolts

All good advice, maybe file very small "flat" on side of each stud to get better hold with Vice-Grips, take it real slow and easy, with preference for not breaking studs off flush with case! I have a 1999 90HP Yamaha also, and dread the day if and when I need to remove heads, exhaust covers, because I'm probably going to bust a few bolts. Let us know how you come out and good luck!

 

[robert graham]

Re: 90hp broken bolts

All good advice, maybe file very small "flat" on side of each stud to get better hold with Vice-Grips, take it real slow and easy, with preference for not breaking studs off flush with case! I have a 1999 90HP Yamaha also, and dread the day if and when I need to remove heads, exhaust covers, because I'm probably going to bust a few bolts. Let us know how you come out and good luck!

 

[bkwapisz]

Re: 90hp broken bolts

Do you have a welder? I'd try to put a nut over that stub and then plug weld it on, which will also heat the bolt really fast and most likely break it loose. Then just put a socket on there.

 

[markoc85]

Re: 90hp broken bolts

Great thanks, I will try all of these great suggestions and try to be patient!

 

[kenmyfam]

Re: 90hp broken bolts

Do you have a welder? I'd try to put a nut over that stub and then plug weld it on, which will also heat the bolt really fast and most likely break it loose. Then just put a socket on there.

This one works very well, however I did not know if a welder was available. Bear in mind that a stainless bolt needs a stainless nut with stainless welding rods for best effect.

 

[bkwapisz]

Re: 90hp broken bolts

This one works very well, however I did not know if a welder was available. Bear in mind that a stainless bolt needs a stainless nut with stainless welding rods for best effect.

Very true, I didn't think of that. Also, if you MIG it the heat will be such that it'll probably work loose form the heat alone.

Aside from that, I'd heat the hell out of those studs where they enter the block with a torch if you can't weld to the studs, then look at the above posts for removal instructions on the bare studs. I have found (through working on old cars) that heat usually does the trick on most stuck metal-to-metal situations.

 

[jonesg]

Re: 90hp broken bolts

2 jamb nuts on the stud , spray penetrating release and heat.
If its stuck due to rust a welder will burn the rust away,
but if its salt a welder won't touch the salt, tried that recently.
Also stainless bolts don't help with salt residue , just rust.

 

[fire7882]

Re: 90hp broken bolts

I've also found that hitting the top of the stuck bolt with a hammer will jar the bolt enough to loosen it up sometimes. This in combination with the other suggestions should get it done

 

[relstabw]

Re: 90hp broken bolts

All good ideas. Just one thing to add. A small pipe wrench works much better than vise grips. PB Blaster works wonders. After heating slightly it will flow into the threads.

 

[alangf]

Re: 90hp broken bolts

Two of the bolts broke off when I removed my exhaust cover today to replace the gaskets.

As you can see from the photo both have stubs poking out. I can get vice grips on each of them but they just slip on the stub when I twist.

Does anyone have a good recipe for getting broken bolts out without drilling?

I've already tried expletives and screaming as loud as I can, would beating my wife help? Just kidding! Any help much appreciated.

You've gotten a lot of good advice here. I would suggest you moderately heat the stub and cool it with penetrating oil PB Blaster is good, Kroil is also good, as are several other products. Make sure you do not heat the stub to the point where it ignites the penetrating oil. As the stub cools it will draw the penetrating oil into the threads. Several applications of penetrating oil and heat may be needed. Patience is indeed a virtue here. If you can once get the stub to move at all you have won! Just keep moving the stub back and forth (in and out if you prefer) and you will be able to move it a little further each time until you have it completely removed. Good luck!

 

[markoc85]

Re: 90hp broken bolts

I've had heaps of fantastic suggestions here, I think combined willpower alone was enough to shift these puppies! We've all acquired a good arsenal to try on future antisocial fasteners - nice work.

The great news is I've dominated both bolts - starting with deep breathing and ice cream to quell the rage followed by periodic blowtorching and spraying with CRC over the course of a day, plus a new pair of vice grips and I finally got them to wiggle, stoked!

 

[kenmyfam]

Re: 90hp broken bolts

I've had heaps of fantastic suggestions here, I think combined willpower alone was enough to shift these puppies! We've all acquired a good arsenal to try on future antisocial fasteners - nice work.

The great news is I've dominated both bolts - starting with deep breathing and ice cream to quell the rage followed by periodic blowtorching and spraying with CRC over the course of a day, plus a new pair of vice grips and I finally got them to wiggle, stoked!

Glad to hear it.