Post by sixpack on Apr 30, 2010 6:39:17 GMT -5
...And Bolts, too!
I guess I could have posted this under the "Engines" topic,but this thread is more of sharing an experience than it has to do with gab about engines!
As Ya'll know, I've been helping to prepare a 1980 GMC Caballero for
some limited drag racing...nothing radical...just some fun on a limited budget.We've already gathered several goodies to help the little but
honorable 305 c.i. muster some "gusto" on the 1/4 mile.
As the Sun finally announced it's appearance yesterday (after 3
days of miserable rain and wind) I decided that the timing was right to remove all the smog and pollution control crap along with the
archaic exhaust manifolds in preparation for the Hooker long tube
competition headers and Jegs custom dual exhaust sytem.
Things went well and primarily uneventful until...Yup!!!
The center bolt on the pFTL!enger side of the engine was the only one we could not "drown" in WD40, due to it's lack of access caused by the spark plug heat shield.So, like the Good driveway mechanic that I am( ;D) I got out the 22", 1/2 "- drive breaker bar
and proceeded to gradually apply slow, constant counter-clockwise pressure in an effort to break this one,stubborn bolt loose.
Well, after some applied muscle, it finally broke loose...
RIGHT IN THE CYLINDER HEAD!!!
So, what do I do now? Okay...I'll fall back on my years as a tool and die maker and drill into the bolt and remove it with a thread extractor.(Easy-Out to most folks) Drilling was difficult as the bolt was at a 20' inverted angle.I went to my arsenal and pulled out my Air-Driven (Yes, Shabba - Air Driven ) right angle drill which was small enough to fit in the small confine of space that I was working in.After centering with a stubby center-drill ,I gradually worked up to 1/4" - in 1/64th increments. That feat alone took the better part of 1 & 1/2 hours. Now for the thread extractor...Started
the hardened steel thread extractor and proceeded to slowly wrench on it between liberal squirts of penetrating oil, with no success. Put a little more pressure on it and ...BINGO!
Yup...broke the damned easy-out in the drilled out bolt It took me
an hour and a half to prepare.My Adrenaline level was pumping as I contemplated my next move.I got a long drift punch and a 12 ounce
mechanics ball-pein hammer and kept on hitting the broken extractor all around it's circumference.After about 15 minutes of this nerve wracking process...VOILA...the extractor falls out of the broken bolt hole and onto the driveway pavement.But now what?
I still have a broken exhaust bolt in the cylinder head! Ahh-but wait!
I went to the tool locker and pulled out my trusty drill and tap set.
I guaged the tap size @ 3/8"-16. I took the appropriate tap drill,
which was 5/16" and SLOWLY enlarged the hole in the broken bolt
to accept the 3/8" tap...It went well, and after drilling I started the tedious and delicate process of re-tapping the drilled out hole in the block to accept the new bolt. SUCCESS!
And to think that the whole process took only THREE AND A HALF HOURS!!! Well, needless to say, I have a few less hairs on my head
(what's left,anyhow) but at least now we can proceed with the installation of the headers and the dual exhaust system!
More on that next week.
Well, that was an ear-ful...thanks for lookin' and Good Luck at the Races!
Best Regards,
Sixpack
I guess I could have posted this under the "Engines" topic,but this thread is more of sharing an experience than it has to do with gab about engines!
As Ya'll know, I've been helping to prepare a 1980 GMC Caballero for
some limited drag racing...nothing radical...just some fun on a limited budget.We've already gathered several goodies to help the little but
honorable 305 c.i. muster some "gusto" on the 1/4 mile.
As the Sun finally announced it's appearance yesterday (after 3
days of miserable rain and wind) I decided that the timing was right to remove all the smog and pollution control crap along with the
archaic exhaust manifolds in preparation for the Hooker long tube
competition headers and Jegs custom dual exhaust sytem.
Things went well and primarily uneventful until...Yup!!!
The center bolt on the pFTL!enger side of the engine was the only one we could not "drown" in WD40, due to it's lack of access caused by the spark plug heat shield.So, like the Good driveway mechanic that I am( ;D) I got out the 22", 1/2 "- drive breaker bar
and proceeded to gradually apply slow, constant counter-clockwise pressure in an effort to break this one,stubborn bolt loose.
Well, after some applied muscle, it finally broke loose...
RIGHT IN THE CYLINDER HEAD!!!
So, what do I do now? Okay...I'll fall back on my years as a tool and die maker and drill into the bolt and remove it with a thread extractor.(Easy-Out to most folks) Drilling was difficult as the bolt was at a 20' inverted angle.I went to my arsenal and pulled out my Air-Driven (Yes, Shabba - Air Driven ) right angle drill which was small enough to fit in the small confine of space that I was working in.After centering with a stubby center-drill ,I gradually worked up to 1/4" - in 1/64th increments. That feat alone took the better part of 1 & 1/2 hours. Now for the thread extractor...Started
the hardened steel thread extractor and proceeded to slowly wrench on it between liberal squirts of penetrating oil, with no success. Put a little more pressure on it and ...BINGO!
Yup...broke the damned easy-out in the drilled out bolt It took me
an hour and a half to prepare.My Adrenaline level was pumping as I contemplated my next move.I got a long drift punch and a 12 ounce
mechanics ball-pein hammer and kept on hitting the broken extractor all around it's circumference.After about 15 minutes of this nerve wracking process...VOILA...the extractor falls out of the broken bolt hole and onto the driveway pavement.But now what?
I still have a broken exhaust bolt in the cylinder head! Ahh-but wait!
I went to the tool locker and pulled out my trusty drill and tap set.
I guaged the tap size @ 3/8"-16. I took the appropriate tap drill,
which was 5/16" and SLOWLY enlarged the hole in the broken bolt
to accept the 3/8" tap...It went well, and after drilling I started the tedious and delicate process of re-tapping the drilled out hole in the block to accept the new bolt. SUCCESS!
And to think that the whole process took only THREE AND A HALF HOURS!!! Well, needless to say, I have a few less hairs on my head
(what's left,anyhow) but at least now we can proceed with the installation of the headers and the dual exhaust system!
More on that next week.
Well, that was an ear-ful...thanks for lookin' and Good Luck at the Races!
Best Regards,
Sixpack