****!!!!! Intake install gone awry. Please Help!?! =PICS=

badstang123 · Jul 9, 2007

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Things are going smoothly....

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Things take a turn...but I take it in stride, head to the store, and pick up an ez-out

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Now I don't know what I'm going to do....

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Any and All, thoughts, idea, or possible solutions would be greatly appreciated. Right now the tip of the EZ-out is in the center of the bolt still in the head. And none of my drill bits are putting a dent into digging through the damn thing

badstang123 · Jul 9, 2007

New heads?

Stanger007 · Jul 9, 2007

If you can get a small punch, chisel or nail in there on a protruding bit of the ezout, you can hammer it around counter clockwise.

Use PB blaster on it first.

Wes

badstang123 · Jul 9, 2007

I've been trying that as well as chipping it out. The things in there pretty good. I'm sure with enough persuasion I'll get it out eventually. I've stopped working on it for a now since I'm having a BBQ at my house (My little brother got back from Iraq today for two weeks leave ) I'll get back to it later and hopefully many of you will have good ideas for me. Thanks.
- Justin

fordtech28 · Jul 9, 2007

Get a good set of drill bits start with the smallest bit available and work your way up to a size smaller than the extractor bit with alot of PB blaster.Then use the extractor bit in reverse and you should be in business.Use a nail or a hole punch to mark the center of the bolt so the drill bit can start straight.Good Luck

BlownFiveLiter · Jul 9, 2007

Take the head off, it'll save you a LOT of aggrivation on a workbench than it would still in the car, getting metal flakes in the engine. Luckily, it's one of the end bolts, so it goes all the way through and you can get to it from the bottom. I had a set of GT40P heads I sold that had a bolt broken off in them, and I was able to drill it out from the bottom side of the head using a bit that was just smaller than the bolt itself. If you have a steady hand, you can do it with a hand drill and spare the threads.

cbarr300 · Jul 9, 2007

I've heard of people using a carbide bit (a couple of them) to drill through the High-density ez-out.

They're very brittle though so you have to make sure your are going straight down on it and the drill doesn't move around...also, pb blaster is your friend.

badstang123 · Jul 10, 2007

It looks like I'm screwed. All of my craftsman carbide tip bits are either making no progress or breaking. Any kind of punch or sharp point chisel type piece I use, the metal just mushrooms out and doesn't chip the EZ-out at all. And then on top of this, the outside edge of the head where the bolt hole is crumbled off. This might really end up with me replacing the heads. Pretty soon I'm not going to know what else to do

final5-0 · Jul 10, 2007

I feel for ya ... been there ... done that

When the tool breaks like that ... it only makes it much worse

You can do all that has been suggested and sooner or later .....
one or more of those methods will work and you will be good to go

Here is the most important thing IMHO

Learn from this experience :Word:

Those bolts can get stuck good

In the future ......
use a tap or thread chaser to get the hole threads good & clean
use a die to clean up the bolt threads

Then use anti seize if Aluminum
or
at least some kind of really good lube if Iron

You'll find it comes apart much easier the next time

Almost forgot ... Good Quality replacement bolts are not a bad thing

Grady

94-302-vert · Jul 10, 2007

Time for some GT40 heads... if you are gonna get that far into it you may as well change them out... Then you are jsut a cam and tune away from H/C/I later...

badstang123 · Jul 10, 2007

final5-0 said:
In the future ......
use a tap or thread chaser to get the hole threads good & clean
use a die to clean up the bolt threads

Then use anti seize if Aluminum
or
at least some kind of really good lube if Iron

You'll find it comes apart much easier the next time

Almost forgot ... Good Quality replacement bolts are not a bad thing

Grady

This is the first time the lower intake has ever been off since the car was brand new. The block, heads, and intake were all factory, so it's not a mistake I made. But you can bet your ass, I'll be careful when putting it together. And I already have grade 8 anodized bolts for when I put it back together. The funny thing is all the other bolts came right out. Some even only felt as if they were hand tight. But that one snapped and I hadn't even put too much pressure on it yet.
- Justin

urban96 · Jul 10, 2007

i bet u can find someone local (or atleast close) thats got a set of stock heads their willing to give away

final5-0 · Jul 10, 2007

badstang123 said:
This is the first time the lower intake has ever been off since the car was brand new. The block, heads, and intake were all factory, so it's not a mistake I made. But you can bet your ass, I'll be careful when putting it together. And I already have grade 8 anodized bolts for when I put it back together. The funny thing is all the other bolts came right out. Some even only felt as if they were hand tight. But that one snapped and I hadn't even put too much pressure on it yet.
- Justin

Of course Justin ... Everybody can relate

We all were in that same situation the first time we tore our motor apart

The deal is ... some of those bolts are involved with water
and
Some of the time ... you can even get involved with gasket sealer

I usually don't pay too much attention to pics
but
In this case

Be careful those inj's don't drop away from the rail :Word:
don't wanna crack any of those Pintle Caps

Hope that bolt breaks loose easily for ya

Grady

badstang123 · Jul 10, 2007

If I end up having to do heads, honestly, I'll probably rip the whole motor out and put a new longblock in. I know it's excessive but it's something I planned on eventually, so we'll see how this plays out and I'll go from there.

I went to Sears and looks like I'm going to try some Cobalt drill bits. On the label it says that they are for all types of metal including "hard". They seem to be working a little better than the Carbide so far, so I hope now it's only a matter of time and patience.

Thanks again for the input guys
- Justin

fastgtfairlane · Jul 10, 2007

i had the exact thing happen to me, except i had both front bolts break off. i broke an ez out in the bolt also. i got some low speed titanium bits and slowly drilled the hole out. the low speed bits cut right through it. make sure to have some good penetrating oil to keep your bits from overheating. it took about an hour and a half to do both. just take your time and make sure the bits are completely center.

GT_green_GT · Jul 10, 2007

i also had the front two break off on me. The engine had never had the intake off before. Snaped of like it was nothing. I spent two hours drilling them out with lots of fluid on the bit. I was able to chase the threads and use it.

oh and i found it was easier to go from the bottom of the head.

ShortThrow50 · Jul 10, 2007

you wont need a new head. I have had this happen before on one of my jet skis. I took it to the local machine shop and he removed the easy out and bolt for like 20 bucks. The guy said to me " another eazy out lol". " I dont understand why people attempt it when the condidtion is that bad". I just laughed with him.

SeventyMach1 · Jul 10, 2007

Keep it lubed .... keep it straight .... and keep it slow. It will come out.

OMG, what did I say? Serioiusly though, that is the key.

badstang123 · Jul 10, 2007

SeventyMach1 said:
Keep it lubed .... keep it straight .... and keep it slow. It will come out.

I think that might replace the quote in your sig as the best quote in SN history

SeventyMach1 · Jul 11, 2007

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