GM LS Broken Exhaust Manifold Bolt Fix (step by step with pics)"

[Curbdog17]

Thanks for the tip. You just helped me out a ton.

[GASoline71]

Sweet! Glad it was of some help!

Gary

[binford]

Looks like I get to replace the last two bolts on my 6.0

I've done the welding thing before on axle studs that have broken on 4x4's.
I used an arc welder with a 312 stainless rod, which is similar to missile rod. with a 115,000 psi tensile strength so it wont twist off. It's a fast freeze rod, so you can weld a bit at a time and stack the weld like stacking dimes.
once I have created a new stud to attach a nut to, I switch to a regular 7018 rod.

Taping the washer in place is an awesome idea as it protects the aluminum head from the heat of the weld.
My local welding shop does not carry 312 in mig wire.

I better practice up welding on some 3/8 bolts before going live on my motor

[richards72chevy]

Great write up.I may have missed it some where in the read but shouldn't an old spark plug be put in there and exhaust port covered up to prevent bb's from going in there?

[Macdaddy1]

My 5.3 had 4 exhaust bolts that broke off. I drilled and extracted three of them and the 4th I had to use a helicoil. Next time I am using the welder.