So I recently purchased dyno don headers and removed my manifolds and of course I ended up snapping a bolt that it's recessed slightly into the block. The broken bolt is the on the passenger side and the furthest to the front/radiator. It's proving to be a huge pain in the *** to extract this thing so I'm just wondering if I install the header without this one bolt will it give me any leaks or should I be okay?

 

Youll want to get that bolt out. Do you have a welder or have a friend with one? If so, and if it isn't recessed too far into the head, you can weld a nut to the broken off bolt through the hole in the nut. Just dont weld on it for long, just tac welds. The heat from the welding will help loosen the rust, and the nut will now be the new head of the bolt. Let it cool then take it out.

I would only recommend this if you have experience with a welder or a friend that does.

 

Another exhaust manifold you may get away with it, but headers are too prone to leak as it is. Someone needs to make a jig that will bolt onto the head so you can drill them out straight while they're on the engine. With small to progressively larger collars to step up the bit size. Then retap or helicoil it. Right up front like this one would be a prime candidate.

 

I broke two on mine. I had the heads off so it was a lot easier getting them out on a bench. EZ out worked on one, the other needed the nut weld method. I can't imagine trying to do this with the heads still on/in the car.

 

Always easier to do it with the head out, lol. It depends which location in the car; by the firewall is the pita, but the ones on the front are generally the easiest to get to.

I got lucky with mine, the nut/bolt snapped leaving enough to grab with vice grips, plus beforehand I did 20+ heat cycles with pb blaster in the 2 weeks prior to removing my manifolds. Super lucky lol.