Broken bolt
Thread Starter
Racer
Joined: Mar 2012
Posts: 250
Likes: 1
Broken bolt
I was tightening the mechanical fuel pump cover on my 82. It's not the stock engine but its just a 350 and I have an electric fuel pump now. Anyway, the bolt head got broken off flush with the block. I tried some bits to get it out but it just won't come out. The only thing I can think of is pulling the engine, drilling it out, and tapping it. But I don't have a lift and my shops asking $1200. Any suggestions on how to get this bolt out?
Racer
Joined: Sep 2012
Posts: 259
Likes: 6
Once you have given it your best with using drill bits and then easy outs, I would try to see if possibly someone could weld a stud or bolt onto the broken bolt and then you might be able to get it to come out. You might also try heating the bolt before drilling it. The best will be getting a hole drilled down into it and then going with and easy out. Use the largest drill bit you can.
Good luck.
Good luck.
Melting Slicks
Joined: Jan 2012
Posts: 3,039
Likes: 504
From: myrtle beach sc
Army
Don't know if you have enough room for this, but I worked in maintenance in an automotive parts plant for 34 years. Try cutting down a small chisel and after soaking the broken stub, try spinning the bolt out at it's rim with the ground down chisel. You have to go in a circle with the bolt hole threads. Lou.
Melting Slicks
Joined: Jun 2009
Posts: 2,709
Likes: 3
From: Savannah GA
If it's stuck because it is cross threaded, drill the bolt carefully for the next size smaller (yes smaller, it's just a blocking plate) bolt, tap the hole and Bob's your uncle. A flat washer will aid clamping force. Grease the drill bit and tap well and clean both a lot so you don't fill the oil pan with swarf.
Melting Slicks
Joined: Jun 2009
Posts: 2,709
Likes: 3
From: Savannah GA
If you need more clearance than removing the tire and dust shielding will allow, removing the motor mount bolt on that side will allow you to gently force the engine either up or down a bit to gain better access. HTH.
6th Gear
Joined: Jul 2012
Posts: 6
Likes: 0
Not sure what the diameter of the bolt is, but if it's large enough you should be able to tap the bolt a using a smaller diameter. Then screw a bolt into it that has the new diameter, once it's tightened it should start to turn the broken bolt. Just make sure you tap it with the threads going the direction you need
Corvette Stories
The Best of Corvette for Corvette Enthusiasts
Top 10 Most Expensive Corvettes Ever Sold on Bring A Trailer
Brett Foote
10 Things Every Corvette Owner Needs (2026 Edition)
Michael S. Palmer
8 Most "Only Corvette Owners Understand" Quirks and Problems
Pouria Savadkouei
10 Reasons the C6 Z06 is Still A Performance Benchmark After 20 Years
Joe Kucinski
How Much Horsepower Every Corvette Engine "LOST" in 1972
Joe Kucinski
Top 10 DOs and DON'Ts for Protecting Your Convertible Top!
Michael S. Palmer
Top 10 Most Explosive Corvettes Ever Made: Power-to-Weight Ratio Ranked!
Joe Kucinski
150 hp to 1,250 hp: Every Corvette Generation Compared by the Specs That Matter
Joe Kucinski
8 Coolest Corvette Pace Cars (and Replicas) of All Time
Verdad Gallardo
Safety Car
Joined: Jul 2005
Posts: 3,694
Likes: 833
From: WI
Here's what you do:
Find a nut that's a few sizes larger than the snapped off bolt. The nut should fit over the exposed stud loosely. Take your wirefeed welder and weld the nut to the stud making sure not to weld outside the nut. You basically want to start in the middle and weld in a spiral from the center to the edge. Wait about 10-15 seconds or so and remove it with a socket wrench. The heat from the welding will break the rust bond between the bolt to the block.
This trick works like a champ. I've used it a bunch of times. It's quick too. The whole process will just take a couple minutes. If the stud is broken clean to the block, then you may want to carefully weld the stud and build it up. Maybe cut the nut in half so it's not as tall so you can weld down to the stud. Good luck!
Find a nut that's a few sizes larger than the snapped off bolt. The nut should fit over the exposed stud loosely. Take your wirefeed welder and weld the nut to the stud making sure not to weld outside the nut. You basically want to start in the middle and weld in a spiral from the center to the edge. Wait about 10-15 seconds or so and remove it with a socket wrench. The heat from the welding will break the rust bond between the bolt to the block.
This trick works like a champ. I've used it a bunch of times. It's quick too. The whole process will just take a couple minutes. If the stud is broken clean to the block, then you may want to carefully weld the stud and build it up. Maybe cut the nut in half so it's not as tall so you can weld down to the stud. Good luck!
Drifting
Joined: Mar 2004
Posts: 1,450
Likes: 40
From: Panama City Beach, Florida
Hang on, hang on,
This is just a cover for the where the fuel pump used to be correct?
I would put a good bead of hi-temp silicone around it, tighten the one good bolt carefully - Done. There is no pressure on it, should be fine.
Frank
This is just a cover for the where the fuel pump used to be correct?
I would put a good bead of hi-temp silicone around it, tighten the one good bolt carefully - Done. There is no pressure on it, should be fine.
Frank
Burning Brakes
Joined: Oct 2001
Posts: 1,241
Likes: 4
From: Okinawa Okinawa
Pro
Joined: Oct 2007
Posts: 549
Likes: 5
From: punta gorda florida
