hey guys so I started the tear down of the car today and I got all of the TPI stuff off: Intake, Runners, Plenum. got the valve covers off and went to get the front drivers side bolt and it was kinda stripped. put in my star key and wouldn't ya know I finished it off. so after drilling it then trying to back it out. to no success. and then an over sized socket, a tap and die set. Small Vice Grips. Big vice Grips(too big to fit in the space) I tried dremeling a notch in the head to hit it with a flat head. well needless to say I failed miserably and now have a mangled bolt.. anyone have something that can help me out... need some advice ASAP! Im about to swan dive into on coming traffic. hereare some pics of my handy work

 

Drill the rest of the bolt head off,leaving as much shank as possible,remove the rest after the intake is off.

 

That was the same exact bolt that gave me trouble on my hsr install. I tried heating it up with a blow torch, then tried to screw it out, then I tied to vice grip it out all with no luck. I ended up taking the andle grinder, and grinded more than half the head off, then I look a chisel and hammered the rest of the head off. After removing the head, I pulled the manifold off, then used vice grips to remove the remaining "stud".

 

goto sears or anywhere you can buy your tools local. get a set of these. smack it on. and it should come right out. Spray that bolt down with some penetrating oil also.

 

Weld a bolt to it. If you weld you will know what I'm talking about.

 

A nut! not a bolt. That bolt is a problem about hal of the time, I have broken those off more than once. Always got the bolt out by welding a nut to the remainder (or simply swappig on some alu heads LOL)

 

I had something similar happen. Cut the rest of the head off. Pull off the intake spray some pb blaster or equivalent every couple of hours for a day or so and use your method of choice then. I'm not a welder so I use big vice grips.

 

THIS!!...works every time for me. I use a nut tho

 

Ya, if I have a bolt head thats rounded off I usually weld a nut to it, it also heats the bolt as u weld and it alwasy seems to back right out.

 

Grind the head off or drill through center till head snaps off, then remove intake and deal with it with vice grips or something.