Stupid question, But i have tried everything else

[Krfoote]

I have a mercruiser Inline 6 165 hp that has been sitting for a long time (at least 2 years) the engine looks ok but i decided to so some work and clean it up a bit before i tried to start it up and ran into a snag when i tried to have a look at my cylinders.

The #1 Head bolt is Corroded so bad the head of the bolt is half missing, I have tried welding washers on and removing it that way, the washers just broke off, I have tried heating it up and using multiple tools to grip and turn, still nothing.

I really dont want to have to drill it out if i dont have to because i dont want to ruin the header or anything else, but i am out of ideas-- any suggestions?

 

[sandersps]

Re: Stupid question, But i have tried everything else

Dremel tool

 

[wire2]

Re: Stupid question, But i have tried everything else

Center punch and drill down to the bottom of the hex, first with a 1/8 bit, then larger, to remove the hex head only. Remove all the other bolts, lift the head off. The tension is now off the remaining stud, clamp a small vise-grip onto it & turn it out. Buy 1 new head bolt. Or a set.

Put a magnet beside the head of the bolt you are drilling, it will attract all the drill shavings.

 

[veritas honus]

Re: Stupid question, But i have tried everything else

I have a mercruiser Inline 6 165 hp that has been sitting for a long time (at least 2 years) the engine looks ok but i decided to so some work and clean it up a bit before i tried to start it up and ran into a snag when i tried to have a look at my cylinders.

The #1 Head bolt is Corroded so bad the head of the bolt is half missing, I have tried welding washers on and removing it that way, the washers just broke off, I have tried heating it up and using multiple tools to grip and turn, still nothing.

I really dont want to have to drill it out if i dont have to because i dont want to ruin the header or anything else, but i am out of ideas-- any suggestions?

Are you familiar with a tool called an "Easy-out"? They look somthing like a short stubby drill bit with thick reverse knurled threads. You drill a small pilot hole in the damaged bolt and insert the proper size Easy-out. You screw it in counterclockwise, the knurled threads bite into the inside of the damaged bolt, and it unscrews it easily. You can put the Easy-out into a drill; but use it on a very low speed. Too fast and you may strip the inside of the bolt and not grip. If this happens, you can still try the next size Easy-out. I've got a set from NAPA. They come in just about every size that drill bits and bolts come in so getting the right size shouldn't be a problem. They're not expensive; about the price of good quality drill bits. Good luck with your repairs.

Safe and happy boating always!!!

 

[veritas honus]

Re: Stupid question, But i have tried everything else

Center punch and drill down to the bottom of the hex, first with a 1/8 bit, then larger, to remove the hex head only. Remove all the other bolts, lift the head off. The tension is now off the remaining stud, clamp a small vise-grip onto it & turn it out. Buy 1 new head bolt. Or a set.

Put a magnet beside the head of the bolt you are drilling, it will attract all the drill shavings.

That magnet idea is great... Thanks

Safe and happy boating always!!!