While changing my thermostat the other day I broke off one of the bolts holding the thermostat housing to the manifold. WHat is the easiest way to get the broken half out of the manifold? I'm guessing that I have to drill it out somehow. Thanks for your help in advance.

 

I did the same thing a few years back. I ended up using a drill bit with a long extension on it so I wouldn't have to remove my TPI. Your best bet is to center punch it as close to the center of the bolt as possible. Then use a drill bit a little bit smaller than the bolt. Make sure to drill straight up and down. Then you can try to use an easy out. Do not break the easy out or you'll probably have to buy a new manifold. Other wise, just tap the hole and use an appropriately sized bolt. Use plenty of penetrating oil for a few days before if you are going if you try to remove the bolt with a bolt extractor like an easy out. You might also try heating up the area with a torch (low heat). Make sure not to get it too hot or you will melt or warp the intake. Be careful of the fuel lines too. Good luck.

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1992 Camaro Z28; Engine:383 w/Edelbrock RPM ported heads. Lunati Solid Roller Cam 224/232 .502/.502, Fluidampner, 1.5 Roller rockers, 30 lb injectors. Haltech E6GM DFI, SLP 1 3/4" headers, 4" Mufflex, T56, 4.10. Super Ram.

Mo steel for Mo stremph!

 

i've had good luck welding a nut on whats left of a broken bolt and using a wrench to back it out. if welding isn't an option i personally would never use an easy out, as you were told if you break a easy out you're screwed. i'd punch it, use a small center drill to geet a place started and then the tap drill a nd then tap the hole. if you screw it up you can always go with a heli coil and if that doesn't work have the hole welded, after you get out the heli coil and bolt and start all over drilling and tapping. better than having to buy a new intake, unless you want a new intake.

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ICON Motorsports

1st & 3rd

 

how much of the bolt is left? if it is still sticking out you can try this (did it on header bolts..)

-thread the "stud" so that you can put some nuts on it
-put two nuts on it and tighten them against each other really tight (locked together..)
-use a wrench on the bottom nut and turn it to remove the bolt, the top nut should keep the bottom one from turning.