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Snapped a valve cover bolt need help
Posted by: Tre107 ()
Date: January 14, 2018 12:09PM

Well today I finally got around to putting the heads back on my Corvair and I was just finishing up and putting the valve cover on and I snapped one of the bolts. It is flush at the top of the hole and I already tried using a hammer and punch get it out and it didn’t budge. Got any ideas on how to get this out?

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Re: Snapped a valve cover bolt need help
Posted by: MattNall ()
Date: January 14, 2018 12:17PM

Instructions are in the FAQ's

Never tighten a 1/4-20 bolt that tight... Max. torque is in INCH lb.

That's a screwdriver style nut driver just snug with your hand OR just the 7/16" socket and an extension for the handle... no tighter..





MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Re: Snapped a valve cover bolt need help
Date: January 14, 2018 12:24PM

File a flat surface so you can center punch.
Heat the area so you can melt candle wax (paraffin) into the threads.
Use Left Hand Thread drill to drill a hole for the bolt extractor you bought.

If you don't have the extractor set, get one!

With the heat and candle wax I've had broken bolts come out while drilling the hole...

I use an electric heat gun - works great, no worry about flame.


Dan Davis ~ Pierce County, WA ~ CORSA Western Director + Corvairs NW + North Cascades Corvairs + Corvanatics
1966 Corsa Turbo coupe ~ ~ 1966 140 Corsa ~ ~ 1965 Monza 140/4 'Vert Sierra Tan/Fawn ~ 1964 Monza 'Vert (SOLD) ~ 1960 Monza Ermine White/Red PG ++ ~ 1965 Monza 140/4 Evening Orchid w/ ivory/black interior ~ 1962 Monza Wagon 102/4 ~ 1963 Rampside/Scamper ~ 1963 Red/Greenbrier ~ 1969 Ultra Van #468

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Re: Snapped a valve cover bolt need help
Posted by: jjohnsonjo ()
Date: January 14, 2018 01:10PM

[www.amazon.com]

My go to for that type of thing is a spring loaded center punch and reverse drill bits .

[www.harborfreight.com]

J.O.

65 Corsa Turbo Vert
79 Honda XL 500S
69 Honda CL 160 D
2010 BMW F 650 GS
2003 Bounder 36D
2013 KIA Optima SX turbo-AKA ZIPPY (wife,s car)
69 Newport Holiday Sailboat
Baja 150 dune buggy cart
Coleman HS 500 UTV
2016 KIA Sorento SXL Turbo

Bethlehem,Pa

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Edited 1 time(s). Last edit at 01/14/2018 01:13PM by jjohnsonjo.

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Re: Snapped a valve cover bolt need help
Posted by: red monza ()
Date: January 14, 2018 02:33PM

My ol super mechanic saved me many times...once when I broke an easy out in my engine block after about wallering out the block threads trying to remove a broken bolt...he removed it all, took a while and actually used my air hose bring it all out of the block.You would have had to see him do it to believe it.

His first attempt was to take a sharp pointed punch or I prefer a sharpened nail set...and angle it at almost the edge of the broke off bolt and try and drive it out the way it would normally come out, I go about a 45 degree angle...drive it to the left with the angled sharp punch and small hammer..It will usually make its own hole so it does not slip...has worked every time for me so far....maybe a little lubricate also...he also told me on stuck bolts to hit them lightly with a hammer head on as it frees up the threads

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Re: Snapped a valve cover bolt need help
Posted by: Tre107 ()
Date: January 14, 2018 02:41PM

Ok I will try the reverse drill bits thanks you for the help

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Re: Snapped a valve cover bolt need help
Posted by: flamingchariots ()
Date: January 14, 2018 02:59PM

I have a similar problem. When trying to remove one of the upper valve cover bolts, it snapped off (probably because of galling). Bolts usually break off with weird edges and angles. This one broke off with a nub sticking out. What a tease...
I've tried the candle wax business. It has never worked for me, probably because of the local environment (corrosion).
I've used the left-handed drill bits, but they inevitably drift off center. Usually they quickly wear out (HF).
It goes without saying that I've soaked it repeatedly for days with Kroil and PB-blaster.
Finally with winter weather, I gave up. I needed to move the car, which had not been started in ten years. So I put it back together with three bolts on the valve cover and pushed it outside. [corvaircenter.com]




Tre, try looking at this topic: [corvaircenter.com]
I think that the next time I tackle my problem, I'll use The Stig's method.




Kevin
Medina, OH

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Re: Snapped a valve cover bolt need help
Posted by: Tre107 ()
Date: January 14, 2018 03:32PM

I think I will try this method before I go to drilling it out

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Re: Snapped a valve cover bolt need help
Posted by: streblerm ()
Date: January 14, 2018 06:29PM

If you have a mig welder you can build up a weld on the bolt one zap at a time. Then either weld a nut to it or just grab it with vise grips.

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Re: Snapped a valve cover bolt need help
Posted by: MattNall ()
Date: January 14, 2018 06:41PM

That process is in our FAQ's with pics..





MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Re: Snapped a valve cover bolt need help
Posted by: SteveInMarietta ()
Date: January 14, 2018 07:08PM

The welding technique is my method of choice and I used it successfully on several snapped off bolts on the Firebrier. There is nothing more inextractable than a snapped off drill bit or extractor.
Steve

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Re: Snapped a valve cover bolt need help
Date: January 14, 2018 08:59PM

Did you use "anti-seize" thread lubricant?
Should be on virtually every steel thread bolt that enters aluminum.

>- A comprehensive article on this is HERE -<


Dan Davis ~ Pierce County, WA ~ CORSA Western Director + Corvairs NW + North Cascades Corvairs + Corvanatics
1966 Corsa Turbo coupe ~ ~ 1966 140 Corsa ~ ~ 1965 Monza 140/4 'Vert Sierra Tan/Fawn ~ 1964 Monza 'Vert (SOLD) ~ 1960 Monza Ermine White/Red PG ++ ~ 1965 Monza 140/4 Evening Orchid w/ ivory/black interior ~ 1962 Monza Wagon 102/4 ~ 1963 Rampside/Scamper ~ 1963 Red/Greenbrier ~ 1969 Ultra Van #468

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Re: Snapped a valve cover bolt need help
Posted by: SteveInMarietta ()
Date: January 14, 2018 10:45PM

Yes I do. But I'm referring to extracting the studs of old bolts during Firebrier disassembly. A couple of the worst offenders were bolts on the two front bumper outer support brackets. During removal the heads snapped right off. The trick in this situation is to carefully apply the weld to the stud and not the surrounding steel, which is not so much an issue when applying the technique to the aluminum block.
Steve

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Re: Snapped a valve cover bolt need help
Posted by: Tre107 ()
Date: January 15, 2018 06:33AM

I’m just worried that if I mig weld a bead on it that it might get to hot and warp that area or cause other damage to the valve cover surface. Should I be worried about that?

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Re: Snapped a valve cover bolt need help
Posted by: corventure Dave ()
Date: January 15, 2018 07:39AM

May I recommend that if you are not planning on keeping the look 100% stock, say for show purposes...

Replace the valve cover bolts with 1-1/2 inch long all thread studs and use nuts and lock-washers to retain the valve covers. This will save the 1/4-20 aluminum threads in the heads.

smileys with beer

Corventure Dave

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Re: Snapped a valve cover bolt need help
Date: January 15, 2018 08:10AM

Tre107 Wrote:
-------------------------------------------------------
> I’m just worried that if I mig weld a bead on it
> that it might get to hot and warp that area or
> cause other damage to the valve cover surface.
> Should I be worried about that?
<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<>>>>>>>>>>>>>>>>>>>>>>>>>

The MIG method would use very quick bursts to weld the remains of the stud to a nut, putting the weld thru the hole of the nut.
Not likely to create that much excess heat.

File the stud so there is fresh metal, perhaps drill the threads out of the nut for the same reason.

!!! DO NOT use clorinated Brake-Cleaner as a degreaser before welding!!!


Dan Davis ~ Pierce County, WA ~ CORSA Western Director + Corvairs NW + North Cascades Corvairs + Corvanatics
1966 Corsa Turbo coupe ~ ~ 1966 140 Corsa ~ ~ 1965 Monza 140/4 'Vert Sierra Tan/Fawn ~ 1964 Monza 'Vert (SOLD) ~ 1960 Monza Ermine White/Red PG ++ ~ 1965 Monza 140/4 Evening Orchid w/ ivory/black interior ~ 1962 Monza Wagon 102/4 ~ 1963 Rampside/Scamper ~ 1963 Red/Greenbrier ~ 1969 Ultra Van #468

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Re: Snapped a valve cover bolt need help
Posted by: Timothy Shortle ()
Date: January 15, 2018 08:22AM

I am definitely a believer in lubing all fasteners when installing (especially ones going into soft metals). Also makes it much easier if one has to remove it.

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