Broken bolt in the head! - The 1947 - Present Chevrolet & GMC Truck Message Board Network

**Nima** · 10-10-2004, 12:25 AM

Well I bought this chrome vavle cover bolt package from a store close to my house. I was happy that everything was going well with my weekend project. So far I have changed the intake, cleaned all over the engine and ready to put valve covers. I got everything ready but I had a little problem with lining the cover holes with the head holes. Finally everthing lined up and I started inserting the bolts. They were not half way in that they stopped, all of them!. Since I was sure that I cleaned (tapped) all the hole before, I guess I pushe a little hard and them bang! one the bolt broken in the head. After that whenn I compair the new bolts with the original one, I noticed they are a lot longer! almost twice. I don't know what the hell is my problem with differnt legth bolt on this project!. Anyways,I tried to drille out and tap it again which tap broke in it!. Now what? Please give me some clues since I am very scared! Thanks

supercheyenne · 10-10-2004, 12:47 AM

if it's sticking out, try to grind flats on it so you can use a wrench.

**Nima** · 10-10-2004, 01:08 AM

No it is not. It is broken below the head surface.

OLDROCK&ROLLER · 10-10-2004, 06:34 AM

That sucks! But is can be remove with a tap extractor. Be real carefull and use a lot tread taping fluid. Good luck.

Zeke · 10-10-2004, 06:37 AM

Try a left hand drill bit. I bought this set about a year ago on sale and it has more than paid for itself. Only had to us an extractor once ususally the bolt came out with just the drill bit. It's kinda pricey but they have individual sets also. You need a bit that is harder than the tap.
http://www.use-enco.com/CGI/INSRIT?P...PMPXNO=5832147

Tx Firefighter · 10-10-2004, 08:01 AM

I've never seen a drill bit that would even dimple a tap.

Get a tiny punch and a pick and try to tap it counterclockwise. The good thing about it being a tap is that the flutes will allow you to get a bite with a punch or pick than an ease out would.

MOTHERTRUCKERS · 10-10-2004, 09:34 AM

On small bolts like valve cover bolts we have had pretty good luck heating the head with a propane torch a little and using tweezers ground to a point at the end to go between the flutes on the tap, we have also used snap ring pliers in the same manner. GOOD LUCK!

Blue Beard · 10-10-2004, 09:50 AM

There is a welding rod that we use to use for just that issue.

You simply put a nut at the surface and weld from the broken stud out to the top of the nut.

The flux from the weld rod protects the threads.

**Nima** · 10-10-2004, 11:55 AM

Thanks for all the tips. I'll try use them one by one. I''let you know what will be the end!. Meanwhile let me know if you come cross any other tricks.

supercheyenne · 10-10-2004, 05:35 PM

I suggest trying a tap extractor first. It has little legs that go into the flutes of the tap and allow you to turn it back out. I've never damaged threads using one.

Then go to the center punch method suggested by TX. This usually works, but I've messed up a few threads at times. See if you can borrow a spring loaded center punch instead of using a solid one and hammer. Either way, patience is key.

If all else fails try to get a diamond point drill bit (left handed is better).

If you're lazy, find a machine shop that has an electrode burner and have them burn it out for you. This will cost some bucks though. Upside is they shouldn't harm the threads.

10-10-2004, 12:25 AM	#1
Nima Blue 67 Join Date: Apr 2004 Location: Western WA Posts: 1,178	Broken bolt in the head! Well I bought this chrome vavle cover bolt package from a store close to my house. I was happy that everything was going well with my weekend project. So far I have changed the intake, cleaned all over the engine and ready to put valve covers. I got everything ready but I had a little problem with lining the cover holes with the head holes. Finally everthing lined up and I started inserting the bolts. They were not half way in that they stopped, all of them!. Since I was sure that I cleaned (tapped) all the hole before, I guess I pushe a little hard and them bang! one the bolt broken in the head. After that whenn I compair the new bolts with the original one, I noticed they are a lot longer! almost twice. I don't know what the hell is my problem with differnt legth bolt on this project!. Anyways,I tried to drille out and tap it again which tap broke in it!. Now what? Please give me some clues since I am very scared! Thanks

10-10-2004, 06:34 AM	#4
OLDROCK&ROLLER Registered User Join Date: Feb 2004 Location: WHITEVILLE N.C. Posts: 494	That sucks! But is can be remove with a tap extractor. Be real carefull and use a lot tread taping fluid. Good luck. __________________ 72 CHEYENNE 10 SUPER 468/400/3.73

10-10-2004, 06:37 AM	#5
Zeke Active Member Join Date: Jun 2002 Location: L.A. Lower Alabama Posts: 453	Try a left hand drill bit. I bought this set about a year ago on sale and it has more than paid for itself. Only had to us an extractor once ususally the bolt came out with just the drill bit. It's kinda pricey but they have individual sets also. You need a bit that is harder than the tap. http://www.use-enco.com/CGI/INSRIT?P...PMPXNO=5832147 __________________ 1969 C10 350 3spd 1995 GMC 3500 XC 350 dually When Thomas Edison worked late into the night on the electric light, he had to do it by gas lamp or candle. I'm sure it made the work seem that much more urgent. George Carlin

10-10-2004, 08:01 AM	#6
Tx Firefighter Watch out for your cornhole ! Join Date: Jun 2003 Location: Azle, Texas Posts: 14,162	I've never seen a drill bit that would even dimple a tap. Get a tiny punch and a pick and try to tap it counterclockwise. The good thing about it being a tap is that the flutes will allow you to get a bite with a punch or pick than an ease out would. __________________ I'm on the Instagram- @Gearhead_Kevin

10-10-2004, 09:34 AM	#7
MOTHERTRUCKERS Registered User Join Date: Dec 1999 Location: BRADENTON FLA Posts: 3,269	On small bolts like valve cover bolts we have had pretty good luck heating the head with a propane torch a little and using tweezers ground to a point at the end to go between the flutes on the tap, we have also used snap ring pliers in the same manner. GOOD LUCK! __________________ Rest in Peace Ed. Thanks for all the good times.

10-10-2004, 12:47 AM	#2
supercheyenne Registered User Join Date: Dec 1999 Location: Newton, KS, U.S.A. Posts: 1,142	if it's sticking out, try to grind flats on it so you can use a wrench.

10-10-2004, 01:08 AM	#3
Nima Blue 67 Join Date: Apr 2004 Location: Western WA Posts: 1,178	No it is not. It is broken below the head surface.

10-10-2004, 09:50 AM	#8
Blue Beard Registered User Join Date: Jan 2003 Location: Washington State Posts: 8,834	There is a welding rod that we use to use for just that issue. You simply put a nut at the surface and weld from the broken stud out to the top of the nut. The flux from the weld rod protects the threads. __________________ 1970 Chev CST 2003 Harley Fatboy 1975 Chevrolet Step Van 1956 Chev Bel Air 1977 Blazer 2WD For Sale $3000.00 1978 Blazer 2WD For Sale $7000.00 1978 Silverado 2005 Monte Carlo

10-10-2004, 11:55 AM	#9
Nima Blue 67 Join Date: Apr 2004 Location: Western WA Posts: 1,178	Thanks for all the tips. I'll try use them one by one. I''let you know what will be the end!. Meanwhile let me know if you come cross any other tricks.

10-10-2004, 05:35 PM	#10
supercheyenne Registered User Join Date: Dec 1999 Location: Newton, KS, U.S.A. Posts: 1,142	I suggest trying a tap extractor first. It has little legs that go into the flutes of the tap and allow you to turn it back out. I've never damaged threads using one. Then go to the center punch method suggested by TX. This usually works, but I've messed up a few threads at times. See if you can borrow a spring loaded center punch instead of using a solid one and hammer. Either way, patience is key. If all else fails try to get a diamond point drill bit (left handed is better). If you're lazy, find a machine shop that has an electrode burner and have them burn it out for you. This will cost some bucks though. Upside is they shouldn't harm the threads.



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