I took my turbo off to get it rebuilt, and one of the rear bolts was badly cross-threaded. I used a breaker bar to get it off, and part of it snapped in the threaded holes on the flange. So, how should I fix this? Whatever I do, I DO NOT want the flange to warp, and I don't want ANY exhaust leaks. I'll do whatever it takes to fix it right. I'm going to be using stainless gaskets w/ copper gasket spray. Should I...

...drill it out, rethread it, mill the manifold flanges, and use bigger bolts?
...weld on a new flange, and mill the manifold flanges?
...just get a new manifold?


Helpo! I have tons of other crap to worry about on the car. It would be nice to get this unexpected problem figured out.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by full Circling &raquo;</TD></TR><TR><TD CLASS="quote">I took my turbo off to get it rebuilt, and one of the rear bolts was badly cross-threaded. I used a breaker bar to get it off, and part of it snapped in the threaded holes on the flange. So, how should I fix this? Whatever I do, I DO NOT want the flange to warp, and I don't want ANY exhaust leaks. I'll do whatever it takes to fix it right. I'm going to be using stainless gaskets w/ copper gasket spray. Should I...

...drill it out, rethread it, mill the manifold flanges, and use bigger bolts?
...weld on a new flange, and mill the manifold flanges?
...just get a new manifold?


Helpo! I have tons of other crap to worry about on the car. It would be nice to get this unexpected problem figured out.
</TD></TR></TABLE>

you should be able to drill it out and retap is slightly larger. ill assume your flange has the standard 10mm bolts so you will orbably have to go to the next size up in american size. i dont think theres an 11mm bolt (could be wrong though).

 

ok, thanks.

i really don't want this crap to leak. will milling the flanges prevent more unexpected bullshit from happening?

i swear, if i get any exhaust leaks after this, i'm just gonna weld the exhaust housing to the manifold. i'll take care of exhaust leaks like the guys in office space take care of fax machines.




Modified by full Circling at 10:10 PM 9/26/2007

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by full Circling &raquo;</TD></TR><TR><TD CLASS="quote">ok, thanks.

i really don't want this crap to leak. will milling the flanges prevent more unexpected bullshit from happening?

i swear, if i get any exhaust leaks after this, i'm just gonna weld the exhaust housing to the manifold. i'll take care of exhaust leaks like the guys in office space take care of fax machines.




Modified by full Circling at 10:10 PM 9/26/2007</TD></TR></TABLE>

drilling/tapping it isnt going to warp it so unless it was warped to begin with, it shouldnt need to be milled.

 

i think it's alraedy warped then. when i pulled the turbo off, my gasket showed signs of leaking.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by full Circling &raquo;</TD></TR><TR><TD CLASS="quote">i think it's alraedy warped then. when i pulled the turbo off, my gasket showed signs of leaking.</TD></TR></TABLE>

then get it surfaced. better to do it now then wait till its back together and have it start leaking, especially if exhaust leaks annoy you.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by full Circling &raquo;</TD></TR><TR><TD CLASS="quote"> I'll do whatever it takes to fix it right. </TD></TR></TABLE>

take it to a machine/fabrication shop and say this: "Fix this Please!" and point to the broken bolt. lol

If you are not 100% comfortable fixing it yourself than do yourself a favour and take it to someone with experience or you might regret it!

ask about time-serts or threaded inserts. you'll want to avoid a "heli-coil" IMO.

 

^^lol, why didn't i think of that? i think handing the problem over to someone else just makes way too much sense for my brain to comprehend. for some reason it has no problem with putting myself through car problems that involve wrench-throwing frustration time and time again. go figure.

i've heard time-serts are $$$. i'll ask the machine shop about them tomorrow when i let them know what's up.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by full Circling &raquo;</TD></TR><TR><TD CLASS="quote">i've heard time-serts are $$$. i'll ask the machine shop about them tomorrow when i let them know what's up.</TD></TR></TABLE>

the reason I suggested them is because you might not be able to get a bigger bolt through the hole on the turbo.