ive snaped a manifold bolt in my head , ive had a go at drilling it out but ive made it worse haha, could i get the hole welded up ,then re drill it and tap it ?

 

I get 2-3 of these jobs at work a week.. if you know someone with a DC tig have them do this:

clean the **** from around the area
build up filler on top of the broken bolt about 10mm high
get the length of the added filler + bolt red hot with the tig, without melting your added filler "off" the bolt
hit it a few times with a hammer while it's red hot, this will help shift the bolt and loosen the "phospher" i think it's called

you should then be able to put some vice grips on the built up filler part and move the bolt..

i always remove the bolt like i'm tapping a thread, go forward and back forward and back.. if the added filler part snaps off, redo the whole thing..

works great for me, been doing this procedure for years

 

thanks

 

My father is a diesel mechanic and has a nifty way to accomplish this same task.

Place a washer and nut over the broken stud and use a stick welder to fill the nut with weld and use the nut to thread the stud out. The washer is used to keep the weld off the unwanted areas. He uses this method often with great success.

Hope this helps.

 

I like that idea with the washer. That is a neat trick.