broken exhaust bolt

[puddle jumper]

Re: broken exhaust bolt

Why not just weld a nut on the broken stud thread it out. Then mount the muffler the way it should be. We do this all the time and you will be surprised how easy it comes out.

 

[SS MAYFLOAT]

Re: broken exhaust bolt

Why not just weld a nut on the broken stud thread it out. Then mount the muffler the way it should be. We do this all the time and you will be surprised how easy it comes out.

I have to agree with PJ, done the same thing many times with success.

 

[MrBigStuff]

Re: broken exhaust bolt

I used to mess around trying to drill and tap out broken off bolts like this. The hard part is making sure that you punch almost exactly on center as all of the following drilling etc will be based on the accuracy of the first punch mark. Then I found a better approach. I weld a nut onto the broken bolt and use a wrench/socket to take it out. The nut works great as you are welding down through the center of the nut to the bolt shoulder. The welding heat helps to break down the rust bond too. It takes a fraction of the time compared to drilling and easy outs and you don't risk breaking off a hardened tool in the bolt.