I know exactly the bolts your talking about and yes they are small, it just takes some fairly precision welding but it can be done.

 

Theres the problem lol

 

i still say a lil heat n bolt extract kit. I don't mean melt the ****... This reminds me of a friends 5.0 where his ac bracket bolts snapped into head cause they were corroded. That was a nasty extraction...

 

Do it the way I said and you wont have a problem I've extracted hundred of bolts over the years.


For the Future: ALWAYS, run a tap through old threads Everytime you start on a new motor and EVERY time an engine or head comes back from the Machine shop.

 

I did it the way you said, the drill but just won't go into the bolt. It either doesn't do anything, or I break the bit. The threads weren't messed up, I just overtorqued it like a dumbass.

 

If you're breaking bits, you're at the wrong angle and spinning the drill too fast. If all else fails, get a standard bit and drill a small starter whole into the broken bolt and after it's in about the width of the lead from a wood pencil, switch over to the Reverse bit using the largest bit you can fit into the whole that doesn't nick the aluminum.

I wish I were there to help.

 

^ +1 Very true statement

 

Here's my question. What size ratchet were you using when you were tightening them? I'm guessing 3/8 or 1/2, cause if you were using 1/4 inch you probably wouldn't have had a problem.

I put most of my motor together with a 1/4 inch ratchet. Most of the bolts are small and don't need to be crazy torqued. The only thing I didn't use 1/4 inch for were the heads, timing cover, and intake. All the other little odds and ends a 1/4 inch worked perfect.

My service manager told me this when I first started my job:

"If you use the torque spec tighten till it snaps then back off two turns, you're not gonna go very far in this business."

 

This is mostly a repeat but one trick for stuck bolts - heat and a candle - heat up the bolt and stick a candle on it the wax will penetrate into the threads and loosen it - seems to me penetrating oil works just as well though.

In my experience with this - just take your time - you'll probably go through several drill bits but start small, go slow (it takes forever sometimes), then move up after you have a deep enough hole - if you're off center - use a center punch next time - oh and make sure your cooling it with cutting oil or some spray oil.

If you screwed up to bad and they're a way off - center hole or you just cant get it - take it to a machine shop and use this as a "lesson's learned" for next time.

Someday you'll be the one on here posting tips for someone ....